Internal support for vacuum insulation structure

Abstract

The invention discloses a vacuum insulation appliance. The vacuum insulation appliance includes a cabinet defining at least one compartment. The cabinet body includes an outer envelope having an inner surface and a liner assembly having an inner surface. The inner liner assembly is coupled to the outer envelope and defines an insulating cavity therebetween. At least a portion of a vacuum is defined within the insulative cavity biasing the outer envelope and the liner assembly toward the insulative cavity. A plurality of supports having a substantially spherical structure are disposed in the insulating cavity. The hollow interior volume of each support is in fluid communication with the insulating cavity through a plurality of apertures defined by each support. The plurality of supports are configured to support the outer envelope and the liner assembly.

Description

Technical Field

[0001] The present disclosure relates generally to internal supports for appliances, and more particularly, to internal supports for vacuum insulated appliances. Summary of the invention

[0002] According to one aspect of the present disclosure, a vacuum insulated apparatus includes a cabinet defining at least one compartment. The cabinet includes an outer envelope having an inner surface and a liner assembly having an inner surface. The liner assembly is coupled to the outer envelope and defines an insulating cavity therebetween. At least a partial vacuum is defined within the insulating cavity, biasing the outer envelope and the liner assembly toward the insulating cavity. A plurality of supports having a substantially spherical structure are disposed in the insulating cavity. The hollow interior volume of each support is in fluid communication with the insulating cavity through a plurality of orifices defined by each support. The plurality of supports are configured to support the outer envelope and the liner assembly.

[0003] According to another aspect of the present disclosure, a vacuum insulated refrigerator includes a structural envelope defining a refrigeration compartment. The structural envelope defines an insulating cavity and a partial vacuum is defined within the insulating cavity. A pressure differential between the external atmosphere and the insulating cavity biases the structural envelope toward the insulating cavity. A plurality of supports having a substantially spherical structure are disposed in the insulating cavity. The hollow interior volume of each support is in fluid communication with the insulating cavity through a plurality of orifices defined by each support. The plurality of supports are configured to support the bias of the structural envelope against the pressure differential.

[0004] According to another aspect of the present disclosure, a method for manufacturing a vacuum insulated cabinet includes: providing an outer envelope; positioning at least one liner within the outer envelope to define an insulating cavity therebetween, the at least one liner defining at least one compartment; and positioning a plurality of supports within the insulating cavity, each support defining an interior volume and including a plurality of apertures in fluid communication with the interior volume. The method further includes: coupling a decorative partition assembly to the outer envelope and the at least one liner to seal the insulating cavity; and drawing at least a partial vacuum within the insulating cavity defined between the outer envelope and the at least one liner.

[0005] These and other features, advantages and objects of the present disclosure will be further understood and appreciated by those skilled in the art by referring to the following description, claims and drawings. BRIEF DESCRIPTION OF THE DRAWINGS

[0006] In the attached picture:

[0007] Figure 1 is a front perspective view of a refrigeration appliance according to the present disclosure;

[0008] Figure 2 is a cross-sectional front perspective view of a refrigeration appliance having a vacuum insulated cabinet and a vacuum insulated door according to the present disclosure;

[0009] Figure 3 is an exploded side perspective view of a cabinet for a refrigeration appliance having a sleeve, a lining assembly and a decorative partition assembly according to the present disclosure;

[0010] Figure 4 is a side perspective view of a refrigeration appliance according to the present disclosure;

[0011] Figure 5 According to the present disclosure Figure 3 A front view of a decorative partition member;

[0012] Figure 6 According to the present disclosure Figure 3 A rear elevation view of a decorative partition;

[0013] Figure 7 is a side perspective view of an internal support member according to the present disclosure;

[0014] Figure 8 is a side perspective view of a polygonal perimeter of a support surface of a support member for forming a polyhedron according to the present disclosure;

[0015] Fig.9A is a cross-sectional view of a support surface according to the present disclosure, wherein a plane defines a polygonal perimeter of the support surface;

[0016] Fig. 9B is a cross-sectional view of a support surface according to the present disclosure, wherein a plane defines a polygonal perimeter of the support surface;

[0017] Fig. 9C is a cross-sectional view of a support surface according to the present disclosure, wherein a plane defines a polygonal perimeter of the support surface;

[0018] Fig.10 is a side perspective view of an internal support member according to the present disclosure;

[0019] Fig.11A is an enlarged partial cross-sectional view of a cabinet including a support member disposed in an insulating cavity according to the present disclosure;

[0020] Fig. 11B is an enlarged partial cross-sectional view of a cabinet including a support member disposed in an insulating cavity according to the present disclosure;

[0021] Fig. 11C is an enlarged partial cross-sectional view of a cabinet including a support member disposed in an insulating cavity according to the present disclosure;

[0022] Fig.11D is an enlarged partial cross-sectional view of a cabinet including a support member disposed in an insulating cavity according to the present disclosure; and

[0023] Fig.12 The present invention is a flow chart of a method for manufacturing a vacuum insulation structure according to the present invention.

[0024] The components in the figures are not necessarily to scale, emphasis instead being placed upon illustrating the principles described herein. DETAILED DESCRIPTION

[0025] The embodiments shown herein reside primarily in combinations of method steps and apparatus components related to internal supports for vacuum insulation structures. Therefore, where appropriate, apparatus components and method steps have been represented in the drawings by conventional symbols, and only those specific details relevant to understanding the embodiments of the present disclosure are shown so as not to obscure the present disclosure with details that would be obvious to one of ordinary skill in the art having the benefit of the description herein. In addition, like reference numerals in the description and drawings represent like elements.

[0026] For the purpose of this description, the terms "upper", "lower", "right", "left", "rear", "front", "vertical", "horizontal" and their derivatives will refer to the following: Figure 1 The disclosure herein shall be oriented in the context of the present invention. Unless otherwise specified, the term "front" shall refer to the surface of the element closer to the intended observer, and the term "rear" shall refer to the surface of the element farther from the intended observer. However, it should be understood that the disclosure may take various alternative orientations unless expressly specified to the contrary. It should also be understood that the specific devices and processes shown in the drawings and described in the following specification are merely exemplary embodiments of the inventive concepts defined in the appended claims. Therefore, unless the claims expressly state otherwise, specific dimensions and other physical characteristics associated with the embodiments disclosed herein should not be considered limiting.

[0027] As used herein, the terms "including," "comprises," "comprising," or any other variations thereof, are intended to cover a non-exclusive inclusion, such that a process, method, article, or apparatus that includes a list of elements includes not only those elements but may also include other elements not expressly listed or inherent to such process, method, article, or apparatus. An element preceded by "comprises..." does not, without more constraints, exclude the presence of additional identical elements in the process, method, article, or apparatus that includes the element.

[0028] refer to Figures 1 to 12, reference numeral 10 generally designates a vacuum insulation structure including a cabinet 12 defining at least one compartment, typically including a refrigeration compartment 14 and a freezer compartment 16. The cabinet 12 includes an outer envelope 18 having an inner surface 20 and a liner assembly 22 having an inner surface 24, the liner assembly including at least one liner 22, which typically includes a refrigeration liner 22a and a freezer liner 22b. The liner assembly 22 is coupled to the outer envelope 18 and defines an insulating cavity 26 therebetween. At least a partial vacuum 28 is defined within the insulating cavity 26, biasing the outer envelope 18 and the liner assembly 22 toward the insulating cavity 26. A plurality of supports 30 are disposed in the insulating cavity 26, the plurality of supports may include a first plurality of supports 30a, a second plurality of supports 30b, and a third plurality of supports 30c, the supports having a substantially spherical structure 32. The substantially spherical structure 32 defines a hollow interior volume 34 of each support member 30 that is in fluid communication with the insulation cavity 26 through a plurality of apertures 36, which may include a first aperture 36 and a second aperture 36 defined by each support member 30. The supports 30 are configured to support the outer envelope 18 and the liner assembly 22.

[0029] Still reference Figures 1 to 4 , the vacuum insulated appliance 10 is shown as a refrigerating appliance. The refrigerating appliance 10 is shown as a bottom mounted refrigerator having an upper compartment configured as a refrigerating compartment 14 and a lower compartment configured as a freezing compartment 16 .

[0030] The cabinet 12 of the refrigeration appliance 10 shown includes a first insulating door 50a and a second insulating door 50b. The first insulating door 50a and the second insulating door 50b (which can be collectively referred to as insulating door 50) can have a substantially similar configuration, as further discussed herein. In this way, the refrigeration compartment 14 and the freezing compartment 16 defined by the cabinet 12 can be sealed with insulating doors 50a, 50b respectively. In addition, in various configurations, the appliance 10 can include a cabinet 12, which at least defines the first compartment and the second compartment sealed with insulating door 50. The appliance 10 can be, for example, a bottom-mounted French door refrigerator, a top-mounted refrigerator, a split refrigerator, a 4-door French door refrigerator and / or a 5-door French door refrigerator. In addition, the present disclosure is not limited to refrigerators. The appliance 10 can be, for example, other similar appliances and appliances in a freezer, a cooler, a vacuum insulation structure, and a home and commercial environment. Furthermore, it is contemplated that the vacuum insulated articles 10 disclosed herein may be used in various articles, structures, panels, or assemblies other than articles for insulation purposes.

[0031] The cabinet 12 of the appliance 10 is an insulating structure having an insulating cavity 26 defined between an outer envelope 18 and a liner assembly 22. The outer envelope 18 and the liner assembly 22 can be collectively referred to as a structural envelope defining the insulating cavity 26. Similarly, the insulating doors 50 are insulating structures each having an insulating cavity 52 defined between a door envelope 54 coupled to a door liner 56. The insulating cavity 26 may include a support 30 disposed therein for supporting the structural envelope of the cabinet 12, as discussed herein. The insulating cavity 52 of the door 50 may include a support 30 for supporting the door envelope 54 and the door liner 56 in a manner similar to that discussed with reference to the cabinet 12. The cabinet 12 and the insulating door 50 each define an evacuation port for applying a partial vacuum or negative pressure 28 to the insulating cavities 26, 52.

[0032] Still reference Figures 1 to 4 , at least a partial vacuum 28 is defined within the insulating cavities 26, 52, forming the cabinet 12 and the door 50 into a vacuum insulated structure. The at least partial vacuum 28 defines a pressure differential 60 between the exterior 62 of the cabinet 12 and the insulating cavity 26. The pressure differential 60 serves to define an inward compressive force exerted on both the outer envelope 18 and the liner assembly 22, and tends to bias the outer envelope 18 and the liner assembly 22 toward the insulating cavity 26. The pressure differential 60 and the inward compressive force are also exerted on both the door envelope 54 and the door liner 56 of the insulating door 50, and tend to bias the door envelope 54 and the door liner 56, respectively, toward the insulating cavity 52 in a similar manner.

[0033] The outer envelope 18, the door envelope 54, the liner assembly 22, and the door liner 56 are made of materials that at least partially resist bending, deforming, or otherwise deforming in response to inward compressive forces. Such materials for the outer envelope 18, the door envelope 54, the liner assembly 22, and the door liner 56 include, but are not limited to, metals, polymers, metal alloys, combinations thereof, and / or other similar substantially rigid materials that may be used for vacuum insulated appliances and structures.

[0034] refer to Figure 3 , the liner assembly 22 may include a refrigeration liner 22a for defining the refrigeration compartment 14 and a freezer liner 22b for defining the freezer compartment 16. The refrigeration liner 22a and the freezer liner 22b may be separate components that, when coupled together using the trim partition assembly 70, define a mullion gap 64 in the insulating cavity 26 therebetween. The mullion gap 64 may be filled with the support members 30 and placed under at least a partial vacuum 28. The refrigeration liner 22a and the freezer liner 22b may be biased toward the mullion gap 64 in the insulating cavity 26 in a manner generally similar to that discussed with reference to the outer envelope 18 and the liner assembly 22.

[0035] In various embodiments, the refrigeration liner 22a and the freezer liner 22b can be coupled together in the mullion gap 64 that is separate from the decorative partition assembly 70. The refrigeration liner 22a and the freezer liner 22b can still define the mullion gap 64 when coupled together. Although the liner assembly 22 is shown as having two separate liners 22a, 22b, the liner assembly 22 can be a single part or structure that defines the refrigeration compartment 14 and the freezer compartment 16. The liner assembly 22 can also be a single structure that defines the refrigeration compartment 14 or the freezer compartment 16. The liner assembly 22 can generally have a similar shape to the outer envelope 18 to fit within the outer envelope 18 and form the cabinet 12.

[0036] The outer envelope 18 and the liner assembly 22 are generally spaced apart from one another to define an insulating cavity 26. The insulating cavity 26 has a thickness 72 defined by the distance between the inner surface 20 of the outer envelope 18 and the inner surface 24 of the liner assembly 22. In some implementations, the thickness 72 of the insulating cavity 26 is substantially uniform between the inner surface 20 of the outer envelope 18 and the inner surface 24 of the liner assembly 22. In other implementations, the thickness 72 of the insulating cavity 26 can vary. For example, the thickness 72 of the insulating cavity 26 proximate the freezer compartment 16 can be greater than the thickness 72 of the insulating cavity 26 proximate the refrigeration compartment 14.

[0037] In a specific implementation in which the liner assembly 22 includes a refrigeration liner 22a and a freezer liner 22b that define a mullion gap 64, the thickness 72 of the insulating cavity 26 is defined between an inner surface 78a of the refrigeration liner 22a and an inner surface 78b of the freezer liner 22b. The thickness 72 of the insulating cavity 26 in the mullion gap 64 can be substantially similar to the thickness 72 between the outer envelope 18 and the liner assembly 22. However, the thickness 72 of the insulating cavity 26 in the mullion gap 64 can also be different from the thickness 72 of the insulating cavity elsewhere. The thickness 72 of the insulating cavity 26 in the mullion gap 64 can be substantially similar throughout the mullion gap 64, but can also vary.

[0038] Still reference Figure 3 as well as Figure 4 , the outer envelope 18 has a plurality of walls 80, which may include a top wall 82, a bottom wall 84, a rear wall 86, a pair of side walls 88, and a curved wall 90. The bottom wall 84 of the outer envelope 18 may be coupled to a base 92. The curved wall 90 and the base 92 of the outer envelope 18 at least partially define a mechanical compartment 94. Various appliance components 96 may be positioned on the base 92 within the mechanical compartment 94 below the rear wall 86 and proximate to the curved wall 90 of the outer envelope 18. The appliance components 96 positioned within the mechanical compartment 94 may include components of a refrigerant system, which may include portions of a compressor, a condenser, and / or an evaporator assembly. The appliance components 96 may also include a controller, electronic devices, or other components for operating the appliance 10.

[0039] The outer envelope 18 and the inner liner assembly 22 may define a first passage 98 and a second passage 100 to provide access for a service connection 102. The outer envelope 18 and the inner liner assembly 22 each define an aperture that is aligned with one another to form the first passage 98 and the second passage 100. The service connection 102 may be an electrical connection, a fluid connection, a refrigerant system connection, and / or other appliance connection between the refrigeration compartment 14 and the freezer compartment 16 and the exterior of the cabinet 12. For example, the service connection 102 may include a suction tube, a drain tube, and a wiring harness.

[0040] Still reference Figure 3 as well as Figure 5 and 6 , the decorative partition assembly 70 generally couples the outer envelope 18 to the liner assembly 22 to form the cabinet 12. It is contemplated that the decorative partition assembly 70 can be coupled to the outer edge 104 of the outer envelope 18 and / or the outer edge 106 of the liner assembly 22. The decorative partition assembly 70 has a generally rectangular shape, however, it is contemplated that other geometric shapes known in the art can be used. In this way, the decorative partition assembly 70 can substantially not hinder access to the refrigeration compartment 14 and the freezer compartment 16 defined by the cabinet 12.

[0041] The trim partition assembly 70 includes a cross member 110 for defining apertures 112a, 112b corresponding to the refrigeration compartment 14 and the freezer compartment 16 of the appliance 10, respectively. The cross member 110 defines a mullion area 114 between the refrigeration compartment 14 and the freezer compartment 16. The trim partition assembly 70 can define an envelope channel 116 extending along an outer perimeter 118 of the trim partition assembly 70 to accommodate the outer edge 104 of the outer envelope 18. The trim partition assembly 70 can also define a liner channel 120, which can include liner channels 120a, 120b to accommodate the outer edge 106 of the liner assembly 22.

[0042] In some embodiments, the liner channel 120 extends along the inner perimeter 122 of the decorative partition assembly 70 to accommodate the liner assembly 22. In other embodiments, the liner channel 120a can extend along the perimeter 124 corresponding to the orifice 112a of the refrigeration compartment 14 to accommodate the outer edge 106 of the refrigeration liner 22a. The liner channel 120b can extend along the perimeter 126 corresponding to the orifice 112b of the freezer compartment 16 to accommodate the outer edge 106 of the freezer liner 22b. It is contemplated that the decorative partition assembly 70 can define a single combined channel extending along the outer perimeter 118 to accommodate both the outer envelope 18 and the liner assembly 22 therein. The channels 116, 120 can be filled with an adhesive, such as, for example, an epoxy resin. The adhesive is configured to couple the outer envelope 18 and / or the liner assembly 22 to the decorative partition 70 and seal the insulating cavity 26.

[0043] refer to Figure 7 and 8 , the support members 30 have a substantially spherical structure 32 and are configured to support the outer envelope 18 and the liner assembly 22. The support members 30 disposed in the insulating cavity 26 generally resist or resist the bias of the outer envelope 18 and the liner assembly 22 caused by the pressure difference 60 between the insulating cavity 26 and the exterior 62 of the cabinet 12. Each of the support members 30 has a structural frame 148 defining the substantially spherical structure 32. The support members 30 each include a plurality of support surfaces 150, which may include a first plurality of support surfaces 150a and a second plurality of support surfaces 150b and / or first to fourth support surfaces 150c-f defined on the structural frame 148. The support surfaces 150 each have a polygonal perimeter in a plurality of polygonal perimeters 152 or a polygonal perimeter in at least one polygonal perimeter 152, which may include a first polygonal perimeter 152a and a second polygonal perimeter 152b. The plurality of support surfaces 150 having polygonal perimeters 152 may also be referred to as a plurality of polygonal surfaces.

[0044] The polygonal perimeter 152 generally includes a plurality of edges 154, each intersecting at a plurality of vertices 156. The edges 154 and vertices 156 of the polygonal perimeter 152 of each of the support surfaces 150 are coplanar. In other words, each of the plurality of planes 158, which may include a first plane 158a and a second plane 158b, contains the edges 154 and vertices 156 of the polygonal perimeter 152 of the corresponding support surface 150. For example, the first plane 158a contains the edges 154 and vertices 156 of the polygonal perimeter 152 of the first support surface 150c, and the second plane 158b contains the edges 154 and vertices 156 of the polygonal perimeter 152 of the second support surface 150d.

[0045] The sides 154 of the polygonal perimeter 152 of each of the support surfaces 150 are aligned with the sides 154 of the polygonal perimeter 152 of the adjacent support surface 150 to form a polyhedron 160. The aligned sides 154 of the polygonal perimeter 152 may also be referred to as edges 162 of the polyhedron. Each of the support surfaces 150 is adjacent to the same number of support surfaces 150 as the sides 154 of the polygonal perimeter 152 of the support surface 150. In some implementations, the polygonal perimeter 152 of each of the support surfaces 150 is identical to form the polyhedron 160, and each support surface 150 is adjacent to the same number of support surfaces 150 as all other support surfaces 150 of the support member 30.

[0046] In other specific implementations, the support member 30 may include a support surface 150 having a varying polygonal perimeter 152. For example, the first plurality of support surfaces 150a may have a first polygonal perimeter 152a and the second plurality of support surfaces 150b may have a second polygonal perimeter 152b. The first polygonal perimeter 152a may be a pentagon and the second polygonal perimeter 152b may be a hexagon. The first polygonal perimeter 152a and the second polygonal perimeter 152b form a polyhedron 160, which may be a truncated icosahedron. The first polygonal perimeter 152a and the second polygonal perimeter 152b are not limited to pentagons and hexagons, and may be various polygons forming the polyhedron 160. For example, the polyhedron 160 may also be a truncated icosahedron having other polygons as the first polygonal perimeter 152a and the second polygonal perimeter 152b, or having one polygonal perimeter 152. The support member 30 is also not limited to having a support surface 150 with two different polygonal perimeters 152, and may include a support surface 150 having more than two different polygonal perimeters 152 forming the polyhedron 160. The polyhedron 160 is not limited to a truncated icosahedron, and may be various polyhedrons 160 having a substantially spherical structure 32 including an icosahedron.

[0047] Still reference Figure 7 and 8 , and now also refer to Figures 9A to 9C , the structural frame 148 extends along the polygonal perimeter 152 of each of the support surfaces 150 to define the substantially spherical structure 32 of the support member 30. In other words, the substantially spherical structure 32 of the support member 30 is defined by a plurality of support surfaces 150 having polygonal perimeters 152. The support surfaces 150 defined by the structural frame 148 can be aligned with the plane 158 of the polygonal perimeter 152 of each of the support surfaces 150. In such specific implementations, the structural frame 148 and the support surfaces 150 are generally aligned with the polyhedron 160 formed by the polygonal perimeters 152, as shown in FIG. Fig.9A shown.

[0048] However, the structural frame 148 and the support surface 150 are not limited to being aligned with the polyhedron 160. The support surface 150 may extend beyond the plane 158 of the polygonal perimeter 152 (i.e., the support surface is outside the polyhedron 160). For example, the support surface 150 may be concave relative to the plane 158 of the polygonal perimeter 152, such as Fig. 9B As shown. The support surface 150 can also be recessed into the plane 158 of the polygonal perimeter 152 (ie, the support surface is within the polyhedron 160). For example, the support surface 150 can be convex relative to the plane 158 of the polygonal perimeter 152, such as Fig. 9C shown.

[0049] When the volume of the polyhedron 160 is greater than or equal to about 75% of the volume of a sphere circumscribed on the polyhedron 160, the support 30 is considered to be a substantially spherical structure 32. In other embodiments, when the volume of the polyhedron 160 is greater than or equal to about 80%, about 83%, about 85%, about 87%, about 90%, about 93%, about 95% of the volume of a sphere circumscribed on the polyhedron 160, the support 30 is considered to be a substantially spherical structure 32. Additionally or alternatively, when the volume of the support frame 148 and the volume therein of the support 30 is greater than or equal to about 75% of the volume of the sphere circumscribed on the polyhedron 160, the support 30 is considered to be a substantially spherical structure 32. In various implementations, the support member 30 is considered to be a substantially spherical structure 32 when the support frame 148 and the volume therein of the support member 30 is greater than or equal to about 80%, about 83%, about 85%, about 87%, about 90%, about 93%, or about 95% of the volume of a circumscribed sphere on the polyhedron 160. The circumscribed sphere is the smallest radius sphere that intersects each of the vertices 156 of the polyhedron 160.

[0050] The support member 30 may have any combination of support surfaces 150 that are coplanar with, extend beyond, or are recessed into a plane 158 defined by the polygonal perimeter 152 of each support surface 150. In embodiments where the support surfaces 150 are all coplanar with or are all recessed into a plane 158 defined by the polygonal perimeter 152 of each support surface 150, the edges 162 of the polyhedrons 160 are generally aligned with the vertices 164 of the structural frame 148. In embodiments where the support surfaces 150 all extend beyond the plane 158 defined by the polygonal perimeter 152 of each support surface 150, the edges 162 of the polyhedrons 160 are generally aligned with the valleys of the structural frame 148.

[0051] In embodiments where the support surfaces 150 are a combination of coplanar with, extending beyond, or recessed into the plane 158 defined by the polygonal perimeter 152 of each support surface 150, the ridge 162 may be aligned with a vertex, a valley, or an inflection point of the structural frame 148. When two adjacent support surfaces 150 are both coplanar with or recessed into the plane 158 defined by the polygonal perimeter 152 of the adjacent support surfaces 150, the ridge 162 is aligned with the vertex. When two adjacent support surfaces 150 both extend beyond the plane 158 defined by the polygonal perimeter 152 of the adjacent support surfaces 150, the ridge 162 is aligned with the valley. When the adjacent support surfaces 150 each have a different configuration relative to the plane 158 defined by the polygonal perimeter 152 of the adjacent support surfaces 150, the ridge 162 is aligned with the inflection point between the adjacent support surfaces 150 (e.g., one support surface 150 extends beyond the plane 158 and the other support surface is coplanar with the plane 158).

[0052] refer to Figure 7 , the structural frame 148 defines a hollow interior volume 34 within the support member 30. The support member 30 defines a plurality of apertures 36, each in fluid communication with the hollow interior volume 34 of the support member 30. The apertures 36 extend through the structural frame 148 so that the hollow interior volume 34 is in fluid communication therewith when disposed in the insulating cavity 26 of the cabinet 12. The apertures 36 allow a partial vacuum 28 to be placed on the hollow interior volume 34 of the support member 30.

[0053] The apertures 36 may be defined on a single face of the support surface 150 or may be defined on multiple faces of the support surface 150. In various implementations, each support surface 150 may define a corresponding aperture 36. For example, a first aperture 36 may be defined by a first support surface 150c, and a second aperture 36 may be defined by a second support surface 150d. In other implementations, each support surface in the first plurality of support surfaces 150a may define a corresponding aperture 36, while each support surface in the second plurality of support surfaces 150b does not define an aperture 36. Multiple apertures 36 may also be defined in each of the support surfaces 150.

[0054] Each of the orifices 36 has at least one orifice perimeter 180 that defines the orifice 36 in the support surface. The orifice perimeter 180 of each of the orifices 36 can be the same on each of the support surfaces 150. However, the orifice perimeter 180 of each of the orifices can also vary or be different for each of the support surfaces 150, or can be different between the first plurality of support surfaces 150a and the second plurality of support surfaces 150b. In some embodiments, the orifice perimeter 180 of the orifice 36 can have a shape similar to or the same as the polygonal perimeter 152 of the support surface 150. In other words, the orifice perimeter 180 of each of the orifices 36 can extend substantially parallel to the polygonal perimeter 152 of the support surface 150 on which the orifice 36 is defined. In other embodiments, the orifice perimeter 180 of the orifice 36 can be circular, polygonal, or other shapes configured to define an orifice and allow fluid communication between the hollow interior volume 34 of the support member 30 and the insulating cavity 26. As Figure 7 As shown, each of the support surfaces 150 defines a corresponding aperture 36 having a circular aperture perimeter 180 .

[0055] Each of the support surfaces 150 has an area 182 defined within the polygonal perimeter 152. The aperture 36 defined by the support surfaces 150 has an area 184 defined within the perimeter 180 of the aperture 36. The area 184 of the aperture 36 may be greater than or equal to about 40%, greater than or equal to about 50%, greater than or equal to about 60%, greater than or equal to about 70%, greater than or equal to about 80%, greater than or equal to about 90% of the area of ​​the corresponding support surface 150.

[0056] refer to Figure 7 , and now also refer to Figures 10 to 11D , the support 30 is made of a material that resists or substantially resists bending, deforming, or otherwise deforming in response to an inward compressive force 186 toward the hollow interior volume 34. The material can allow the structural frame 148 to shift toward the hollow interior volume 34 along an axis 188 parallel to the compressive force, and allow displacement away from the hollow interior volume 34 along an axis 190 substantially perpendicular to the compressive force 186. These materials can also have low heat transfer coefficients so that heat has difficulty propagating along the support 30. Such materials for the support 30 include, but are not limited to, metals, polymers, metal alloys, combinations thereof, and / or other similar substantially rigid materials that can be used for vacuum insulated appliances and structures.

[0057] The supports 30 each generally engage the inner surface 20 of the outer envelope 18, the inner surface 24 of the liner assembly 22, and a combination of adjacent supports 30 to resist a pressure differential 60 between the exterior 62 of the cabinet 12 and the insulating cavity 26. The pressure differential 60 acts as an inward compressive force 186 toward the hollow interior volume 34 of the supports 30. The supports 30 can compress or flex along an axis 188 parallel to the compressive force 186, thereby causing the supports to bend and flex away from the hollow interior volume 34 along an axis 190 perpendicular to the compressive force 186. By arranging the supports adjacent to other supports 30, the supports 30 can be prevented or at least partially prevented from flexing away from the hollow interior volume 34 of adjacent supports 30. By at least partially preventing flexing away from the hollow interior volume 34 along the axis 190, compression along the axis 188 toward the hollow interior volume 34 can also be prevented or at least partially prevented from occurring.

[0058] The support member 30 having the substantially spherical structure 32 generally has a diameter 200. The diameter 200 is measured from a point on the first support surface 150c to a point on the second support surface 150d on the opposite side of the polyhedron 160 of the first support surface 150c. In various implementations, the diameter 200 of the support member 30 can be approximately equal to, less than or equal to about half, less than or equal to about one third, less than or equal to about one quarter, less than or equal to about one sixth, or less than or equal to about one tenth the thickness 72 of the insulating cavity 26. In other embodiments, the diameter 200 of the support member 30 can be about 7.0 inches, about 6.0 inches, about 5.0 inches, about 4.0 inches, about 3.0 inches, about 2.0 inches, about 1.0 inch, about 0.75 inches, about 0.5 inches, 0.25 inches, about 0.125 inches, or within any range defined by any two of these values ​​(e.g., from 1.0 inches to 7.0 inches, from 0.125 inches to 2.0 inches, from 3.0 inches to 5.0 inches, etc.).

[0059] The supports 30 may be placed or aligned within the insulating cavity 26, or may be randomly disposed within the insulating cavity 26. By aligning the supports within the insulating cavity 26, the support surface 150 may be configured to engage a particular support surface of an adjacent support member 30, the inner surface 20 of the outer envelope 18, and / or the inner surface 24 of the liner assembly 22. The supports 30 may be arranged in a pattern, thereby forming rows and / or columns of the supports 30 within the insulating cavity 26. The supports 30 may also be offset in a pattern when placed or aligned within the insulating cavity 26.

[0060] The supports 30 may also be randomly disposed in the insulating cavity 26. In some implementations, the diameter 200 of the supports 30 may be small enough to be disposed in the insulating cavity 26 by dumping or inserting the supports 30 through a loading port defined on the cabinet 12. The supports 30 generally do not have a particular controlled alignment within the insulating cavity when disposed in this manner. The insulating cavity 26 may be completely filled or substantially filled with the supports 30 to form a substantially continuous layer of the supports 30 in the insulating cavity 26. The cabinet 12 may be vibrated while the supports 30 are disposed in this manner to help the supports 30 settle and engage adjacent supports 30, the inner surface 20 of the outer envelope 18, and / or the inner surface 24 of the liner assembly 22. The supports 30 may also be randomly placed in the insulating cavity 26 before the decorative partition assembly 70 is coupled to the outer envelope 18 and the liner assembly 22.

[0061] like Fig.11A As shown, the diameter 200 of the support member 30 is approximately equal to the thickness 72 of the insulating cavity 26. The first support surface 150c of the support member 30 engages the inner surface 20 of the outer envelope 18, and the second support surface 150d of the support member 30 engages the inner surface 24 of the liner assembly 22. The third support surface 150e and the fourth support surface 150f of the support member 30 typically engage the third support surface 150e and the fourth support surface 150f of the adjacent support member 30, but if positioned at the corner of the cabinet 12, it can engage the inner surface 20 of the outer envelope 18.

[0062] like Fig. 11B As shown, the diameter 200 of the support member 30 is approximately equal to half of the thickness 72 of the insulating cavity 26. The first support surface 150c of the first plurality of support members 30a engages the inner surface 20 of the outer envelope 18, and the second support surface 150d engages the first support surface 150c of the adjacent support member 30 of the second plurality of support members 30b. The second support surface 150d of the second plurality of support members 30b engages the inner surface 24 of the liner assembly 22. The third support surface 150e and the fourth support surface 150f of both the first plurality of support members 30a and the second plurality of support members 30b typically engage the third support surface 150e and the fourth support surface 150f of the adjacent support member 30 in the same plurality of support members 30a, 30b. However, if positioned in a corner of the cabinet 12, the third support surface 150e and the fourth support surface 150f of the first plurality of support members 30a can engage the inner surface 20 of the outer envelope 18. If positioned in a corner of the cabinet 12, the third and fourth support surfaces 150e, 150f of the second plurality of supports 30b may engage the third or fourth support surfaces 150e, 150f of the first plurality of supports 30a.

[0063] like Fig. 11CAs shown, the diameter 200 of the support member 30 is approximately equal to one-third of the thickness 72 of the insulating cavity 26. The first support surface 150c of the first plurality of supports 30a engages the inner surface 20 of the outer envelope 18, and the second support surface 150d engages the first support surface 150c of an adjacent support member 30 of the second plurality of supports 30b. The second support surface 150d of the second plurality of supports 30b engages the first support surface 150c of an adjacent support member 30 of the third plurality of supports 30c. The second support surface 150d of the third plurality of supports 30c engages the inner surface 24 of the liner assembly 22. The third support surface 150e and the fourth support surface 150f of the first plurality of supports 30a, the second plurality of supports 30b, and the third plurality of supports 30c generally engage the third support surface 150e and the fourth support surface 150f of the adjacent support members 30 of the same plurality of supports 30a, 30b, 30c. However, if positioned in a corner of the cabinet 12, the third support surface 150e and the fourth support surface 150f of the first plurality of supports 30a may engage the inner surface 20 of the outer envelope 18. If positioned in a corner of the cabinet 12, the third support surface 150e and the fourth support surface 150f of the second plurality of supports 30b and the third plurality of supports 30c may engage the third support surface 150e or the fourth support surface 150f of the first plurality of supports 30a or the second plurality of supports 30b.

[0064] Although the supports 30 having a diameter 200 that is one-third of the thickness 72 of the insulating cavity 26 are shown as being aligned and forming a grid or structure, the supports 30 are not limited thereto and may be randomly distributed or aligned in a different manner. In an implementation in which the supports 30 are randomly distributed, the support faces 150 may engage adjacent surfaces, including the inner surface 20 of the outer envelope 18 and the inner surface 24 of the liner assembly 22 and / or one or more support faces 150 of adjacent supports 30. The supports 30 may also be aligned such that alternating rows of supports 30 engage the inner surfaces 20, 24 of the outer envelope 18.

[0065] like Fig.11D As shown, the diameter 200 of the support members 30 is less than or equal to about one-tenth of the thickness 72 of the insulating cavity 26. The first plurality of supports 30a and the third plurality of supports 30c generally engage the inner surface 20 of the outer envelope 18 and / or the inner surface 24 of the liner assembly 22, while the second plurality of supports 30b engage adjacent supports 30 from the first plurality of supports 30a, the second plurality of supports 30b, and / or the third plurality of supports 30c. Each of the supports 30a, 30b, 30c may have more than four support faces 150 engaging adjacent surfaces. The supports 30 may be evenly or uniformly aligned and distributed throughout the insulating cavity 26, but may also be randomly placed or distributed therein.

[0066] Still reference Figure 7 and 11A to 11D, and now also refer to Figures 9A to 9C , the support member 30 may include a support surface 150 that is configured to be received or receive the support surface 150 of an adjacent support surface 150. In this way, the support member 30 interlocks with the adjacent support member 30 to form an interlocking support network within the insulating cavity 26. The interlocking support network can prevent the support member 30 from moving due to the inward compression force 186 or other movement of the cabinet 12. For example, the third support surface 150e of the support member 30 can extend beyond the plane 158 defined by the polygonal perimeter 152 of the third support surface 150e, and the fourth support surface 150f of the support member 30 can be recessed into the plane 158 defined by the polygonal perimeter 152 of the fourth support surface 150f. The third support surface 150e of the support member 30 can be received within the recessed fourth support surface 150f on the adjacent support member 30. The support member 30 may include a plurality of recessed surfaces and extended surfaces that are opposite to each other to form an interlocking support member 30. The inner surface 20 of the outer envelope 18 and / or the inner surface 24 of the liner assembly 22 may also include raised or recessed surfaces to engage a support member 30 having a corresponding raised or recessed support surface 150 .

[0067] refer to Figure 7 and 11A 11D, the cabinet 12 may include supports 30 having various diameters 200 disposed within the insulating cavity 26. For example, the cabinet 12 may include a first plurality of supports 30a having a first diameter 200 disposed in the mullion gap 64 between the refrigeration liner 22a and the freezer liner 22b and a second plurality of supports 30b having a second diameter 200 disposed in the remainder of the insulating cavity 26 between the outer envelope 18 and the liner assembly 22. In another example, the cabinet 12 may include a first plurality of supports 30a having a first diameter 200 and a second plurality of supports 30b having a second diameter 200 disposed in the insulating cavity, thereby forming alternating rows of the first plurality of supports 30a and the second plurality of supports 30b. In yet another example, the cabinet 12 may include a first plurality of supports 30a having a first diameter 200 and a second plurality of supports 30b having a second diameter 200 randomly distributed within the insulating cavity 26. The various diameters 200 are not limited to these examples, and may include three or more support members 30 each having the various diameters 200 aligned or randomly distributed within the insulating cavity 26 .

[0068] In addition to the support 30, the insulating cavity 26 of the cabinet 12 may also include one or more insulating materials disposed therein. It is generally contemplated that the insulating material may be a glass-type material, a carbon-based powder, a silicon oxide-based material, a silicon dioxide-based material, an insulating gas, and other standard insulating materials known in the art. The insulating material may substantially fill the insulating cavity 26 around the support 30, forming a substantially continuous layer between the outer envelope 18 and the liner assembly 22. The insulating material may be smaller than the aperture 36 defined on the support 30 to at least partially fill the hollow interior volume 34. After the support 30 is disposed in the insulating cavity 26, the loading port on the cabinet 12 may be used to fill the insulating cavity. When combined with the support 30, the insulating material may provide additional insulating properties for the appliance 10. For example, an insulating material having better insulating properties when not compressed may be used in the cabinet 12 with the support 30. The support 30 will prevent or at least partially prevent the insulating material from being compressed under at least a partial vacuum 28.

[0069] refer to Fig.12 , with further reference to Figures 1 to 11D , a flow chart of a method 300 for manufacturing a vacuum insulation structure 10 is shown. The method 300 includes a step 304 of providing an outer envelope 18. A structural envelope including the outer envelope 18 and a liner assembly 22 defining an insulating cavity 26 may be provided. At step 308, at least one liner 22 or liner assembly 22 is positioned within the outer envelope 18 to define an insulating cavity 26 therebetween. At least one liner 22 or liner assembly 22 defines at least one compartment, which may be a refrigeration compartment 14 and / or a freezing compartment 16. A refrigeration liner 22a may be positioned within the outer envelope 18 to define an insulating cavity 26 therebetween. A freezing liner 22b may be positioned within the outer envelope 18 to define an insulating cavity 26 therebetween and define a mullion gap 64 in the insulating cavity 26 between the refrigeration liner 22a and the freezing liner 22b.

[0070] At step 312, a plurality of supports 30 may be positioned or disposed within the insulating cavity 26. Each of the supports 30 defines a hollow interior volume 34 and includes an orifice 36 in fluid communication with the hollow interior volume 34. A first support surface 150c of each of the plurality of supports 30 may be positioned to engage the inner surface 20 of the outer envelope 18. A second support surface 150d of each of the plurality of supports 30 may be positioned to engage the inner surface 24 of at least one liner 22. The supports 30 may include a plurality of supports 30, which may include a first plurality of supports 30a and a second plurality of supports 30b. A first support surface 150c of each of the first plurality of supports 30a may be positioned to engage the inner surface 20 of the outer envelope 18. A first support surface 150c of each of the second plurality of supports 30b may be positioned to engage the second support surface 150d of the first plurality of supports 30a. The second support surface 150 d of each support member of the second plurality of supports is configured to engage the inner surface 24 of the at least one liner 22 .

[0071] The supports 30 may also be randomly placed within the insulating cavity using a loading port defined on the cabinet 12 formed by a structural envelope having an outer envelope 18 and an inner liner assembly 22. This may include vibrating the structural envelope to allow the supports 30 to settle and fill the insulating cavity 26.

[0072] At step 316, the trim partition assembly 70 can be coupled to the outer envelope and the at least one inner liner 22 to at least partially seal the insulating cavity 26. The outer edge 104 of the outer envelope 18 can be disposed in the envelope channel 116 defined by the trim partition assembly 70 and coupled to the trim partition assembly 70 using an adhesive. The outer edge 106 of the at least one inner liner 22 can be disposed in the liner channel 120 defined by the trim partition assembly 70 and coupled to the trim partition assembly 70 using an adhesive.

[0073] In step 320, insulating material may be disposed within insulating cavity 26 through a loading port defined by cabinet 12. Cabinet 12 may be vibrated to allow insulating material to fill hollow interior volume 34 through apertures 36 of support 30 and around support 30. The insulating material may form a substantially continuous layer within insulating cavity 26.

[0074] In step 324, at least a partial vacuum 28 may be placed in or drawn into the insulating cavity 26 defined by the outer envelope 18 and the inner liner assembly 22 coupled together with the trim partition assembly 70. Step 328 may also include coupling the door 50 to the cabinet 12, adding a refrigeration system, and otherwise completing the assembly of the appliance 10. The steps of the method 300 may be performed in any order, simultaneously, in parallel, repeated, omitted, etc., without departing from the teachings herein.

[0075] Use of the present device can provide a number of advantages. For example, the structural frame 148 of the support 30 is confined to the polyhedron 160 to form a tortuous heat transfer path, thereby reducing heat transfer through the support 30. The orifice 36 that defines the support 30 reduces the heat transfer path on the structural frame 148 by destroying the direct and straight heat transfer path. In addition, the support 30 has a support surface 150 that is limited in surface area due to the orifice 36, which reduces the heat transfer between the adjacent surfaces 30 (e.g., the inner surface 20 of the outer envelope 18) that the support surface 150 engages. In addition, due to the rigid or at least partially rigid nature of the support 30, the support 30 can also allow at least a partial vacuum 28 to be closer to a complete vacuum. When there is a large pressure difference 60 between the insulating cavity 26 and the exterior 62 of the cabinet 12, the support 30 can support the outer envelope 18 and the liner assembly 22. Additional benefits or advantages can be achieved and / or reached.

[0076] The devices disclosed herein are further summarized in the following paragraphs and are further characterized by any and all combinations of the various aspects described therein.

[0077] According to one aspect of the present disclosure, a vacuum insulated apparatus includes a cabinet defining at least one compartment. The cabinet includes an outer envelope having an inner surface and a liner assembly having an inner surface. The liner assembly is coupled to the outer envelope and defines an insulating cavity therebetween. At least a partial vacuum is defined within the insulating cavity, biasing the outer envelope and the liner assembly toward the insulating cavity. A plurality of supports having a substantially spherical structure are disposed in the insulating cavity. The hollow interior volume of each support is in fluid communication with the insulating cavity through a plurality of orifices defined by each support. The plurality of supports are configured to support the outer envelope and the liner assembly.

[0078] According to another aspect, each support member of the plurality of supports has a diameter approximately equal to a thickness between an inner surface of the liner assembly and an inner surface of the outer envelope.

[0079] According to yet another aspect, each support member of the plurality of supports includes a first support surface that engages an inner surface of the outer envelope and a second support surface that engages an inner surface of the liner assembly.

[0080] According to another aspect, each support member of the plurality of supports has a diameter that is less than or equal to about half of a thickness between an inner surface of the liner assembly and an inner surface of the outer envelope.

[0081] According to yet another aspect, the plurality of supports includes a first plurality of supports and a second plurality of supports. Each of the first plurality of supports includes a first support surface that engages an inner surface of the outer envelope and a second support surface. Each of the second plurality of supports includes a third support surface that engages an inner surface of the outer envelope and a fourth support surface. The second support surface of each of the first plurality of supports engages a third support surface of a corresponding support of the second plurality of supports.

[0082] According to another aspect, the plurality of supports includes a first plurality of supports having a first diameter and a second plurality of supports having a second diameter.

[0083] According to yet another aspect, the at least one compartment includes a refrigeration compartment and a freezer compartment. The liner assembly includes a refrigeration liner defining the refrigeration compartment and a freezer liner defining the freezer compartment. The insulating cavity is further defined in a mullion gap between the refrigeration liner and the freezer liner.

[0084] According to another aspect of the present disclosure, a vacuum insulated refrigerator includes a structural envelope defining a refrigeration compartment. The structural envelope defines an insulating cavity and a partial vacuum is defined within the insulating cavity. A pressure differential between the external atmosphere and the insulating cavity biases the structural envelope toward the insulating cavity. A plurality of supports having a substantially spherical structure are disposed in the insulating cavity. The hollow interior volume of each support is in fluid communication with the insulating cavity through a plurality of orifices defined by each support. The plurality of supports are configured to support the bias of the structural envelope against the pressure differential.

[0085] According to another aspect, the structural envelope defines a freezer compartment.

[0086] According to yet another aspect, each support has a diameter approximately equal to the thickness of the insulating cavity.

[0087] According to another aspect, each support has a diameter less than or equal to about half the thickness of the insulating cavity.

[0088] According to yet another aspect, each of the plurality of supports includes a plurality of support surfaces having at least one polygonal perimeter defining a polyhedron having a substantially spherical configuration.

[0089] According to another aspect, each support surface of the plurality of support surfaces includes a corresponding aperture of the plurality of apertures.

[0090] According to another aspect, the plurality of support surfaces includes a first plurality of support surfaces and a second plurality of support surfaces. Each support surface in the first plurality of support surfaces has a first polygonal perimeter of at least one polygonal perimeter. Each support surface in the second plurality of support surfaces has a second polygonal perimeter of at least one polygonal perimeter.

[0091] According to another aspect, the polyhedron is a truncated icosahedron, wherein the first polygonal perimeter is a pentagon and the second polygonal perimeter is a hexagon.

[0092] According to another aspect of the present disclosure, a method for manufacturing a vacuum insulated cabinet includes: providing an outer envelope; positioning at least one liner within the outer envelope to define an insulating cavity therebetween, the at least one liner defining at least one compartment; and positioning a plurality of supports within the insulating cavity, each support defining an interior volume and including a plurality of apertures in fluid communication with the interior volume. The method further includes: coupling a decorative partition assembly to the outer envelope and the at least one liner to seal the insulating cavity; and drawing at least a partial vacuum within the insulating cavity defined between the outer envelope and the at least one liner.

[0093] According to another aspect, at least one compartment includes a first compartment and a second compartment. At least one liner includes a first liner defining the first compartment and a second liner defining the second compartment. The step of positioning at least one liner within the outer envelope includes positioning the first liner within the outer envelope to partially define an insulating cavity therebetween, and positioning the second liner within the outer envelope to partially define an insulating cavity therebetween. The first liner and the second liner partially define a mullion gap within the insulating cavity therebetween.

[0094] According to yet another aspect, each of the plurality of supports includes a first support surface and a second support surface. The step of positioning the plurality of supports within the insulating cavity includes positioning the first support surface of each of the plurality of supports to engage an inner surface of the outer envelope, and positioning the second support surface of each of the plurality of supports to engage an inner surface of at least one liner.

[0095] According to another aspect, the plurality of supports includes a first plurality of supports and a second plurality of supports. Each of the first plurality of supports includes a first support surface and a second support surface, and the second plurality of supports includes a third support surface and a fourth support surface. The step of positioning the plurality of supports within the insulating cavity includes positioning the first support surface of each of the first plurality of supports to engage the inner surface of the outer envelope, positioning the third support surface of each of the second plurality of supports to engage the second support surface of the first plurality of supports, and positioning the fourth support surface of each of the second plurality of supports to engage the inner surface of at least one liner.

[0096] According to yet another aspect, each support member of the plurality of supports has a diameter that is less than about half of a thickness between an inner surface of the at least one liner and an inner surface of the outer envelope.

[0097] Those of ordinary skill in the art will appreciate that the construction of the described disclosure and other components is not limited to any particular material. Unless otherwise described herein, other exemplary embodiments of the disclosure disclosed herein may be formed from a variety of materials.

[0098] For purposes of this disclosure, the term "coupled" (in all its forms, coupling, coupling, coupled, etc.) generally means that two components (electrical or mechanical) are directly or indirectly joined to each other. Such joining may be fixed in nature or movable in nature. Such joining may be achieved by the two components (electrical or mechanical) and any additional intermediate members being integrally formed as a single entity with each other or with the two components. Unless otherwise specified, such joining may be permanent in nature or may be removable or releasable in nature.

[0099] It is also important to note that the construction and arrangement of the elements of the present disclosure shown in the exemplary embodiments are only illustrative. Although only several embodiments of this innovation have been described in detail in the present disclosure, it will be easily understood by those skilled in the art who review the present disclosure that many modifications are possible (for example, the size, size, structure, shape and ratio, parameter value, installation arrangement, use of materials, color, orientation, etc. of various elements) without substantially departing from the novel teachings and advantages of the narrated subject matter. For example, the element shown as being integrally formed can be composed of multiple parts, or the element shown as multiple parts can be integrally formed, the operation of the interface can be reversed or otherwise changed, the length or width of the structure and / or member or connector or other elements of the system can be changed, and the nature or quantity of the adjustment position provided between the elements can be changed. It should be noted that the elements and / or assemblies of the system can be composed of any of a variety of materials providing sufficient strength or durability in a variety of colors, textures, and combinations. Therefore, all such modifications are intended to be included in the scope of this innovation. Without departing from the spirit of this innovation, other substitutions, modifications, changes, and omissions can be made in terms of the design, operating conditions, and arrangement of desired and other exemplary embodiments.

[0100] It should be understood that any of the processes or steps in the described processes can be combined with other disclosed processes or steps to form structures within the scope of the present disclosure. The exemplary structures and processes disclosed herein are for illustrative purposes and should not be interpreted as limiting.

Claims

1. A vacuum insulation device, comprising: A cabinet defining at least one compartment, the cabinet comprising: an outer envelope having an inner surface; and a liner assembly having an inner surface, the liner assembly coupled to the outer envelope and defining an insulating cavity therebetween, wherein at least a partial vacuum is defined within the insulating cavity biasing the outer envelope and the liner assembly toward the insulating cavity; A plurality of supports having a substantially spherical structure disposed in the insulating cavity, wherein the hollow interior volume of each support is in fluid communication with the insulating cavity through a plurality of orifices defined by each support, and wherein the plurality of supports are configured to support the outer envelope and the liner assembly. 2 . The vacuum insulation appliance according to claim 1 , wherein each of the plurality of support members has a diameter approximately equal to a thickness between the inner surface of the liner assembly and the inner surface of the outer envelope. 3 . The vacuum insulation appliance of claim 2 , wherein each of the plurality of supports comprises a first support surface engaging the inner surface of the outer envelope and a second support surface engaging the inner surface of the liner assembly.

4. The vacuum insulation appliance according to any one of claims 1 or 2, wherein each of the plurality of supports has a diameter less than or equal to about half of a thickness between the inner surface of the liner assembly and the inner surface of the outer envelope.

5. The vacuum insulated apparatus according to claim 4, wherein the plurality of supports include a first plurality of supports and a second plurality of supports, and wherein each of the first plurality of supports includes a first support surface and a second support surface engaging the inner surface of the outer envelope, and each of the second plurality of supports includes a third support surface and a fourth support surface engaging the inner surface of the outer envelope, and further wherein the second support surface of each of the first plurality of supports engages the third support surface of a corresponding support of the second plurality of supports. 6 . The vacuum insulation appliance according to claim 1 , wherein the plurality of supports include a first plurality of supports having a first diameter and a second plurality of supports having a second diameter.

7. A vacuum insulated apparatus according to any one of claims 1 or 2, wherein the at least one compartment includes a refrigerating compartment and a freezing compartment, and wherein the lining assembly includes a refrigerating liner defining the refrigerating compartment and a freezing liner defining the freezing compartment, and further wherein the insulating cavity is further defined in a vertical bar gap between the refrigerating liner and the freezing liner.

8. A vacuum insulated refrigerator, comprising: a structural envelope defining a refrigeration compartment, the structural envelope defining an insulating cavity, wherein a partial vacuum is defined within the insulating cavity, and wherein a pressure differential between an external atmosphere and the insulating cavity biases the structural envelope toward the insulating cavity; as well as a plurality of supports having a substantially spherical structure disposed in the insulating cavity, wherein the hollow interior volume of each support is in fluid communication with the insulating cavity through a plurality of orifices defined by each support, and wherein the plurality of supports are configured to support the structural envelope against the bias of the pressure differential.

9. A vacuum insulated refrigerator according to claim 8, wherein the structural envelope defines a freezer compartment. 10 . The vacuum insulated refrigerator according to claim 8 , wherein each support member has a diameter approximately equal to a thickness of the insulating cavity. 11 . The vacuum insulated refrigerator according to claim 8 , wherein each support member has a diameter less than or equal to about half of a thickness of the insulating cavity.

12. The vacuum insulated refrigerator according to any one of claims 8 to 11, wherein each of the plurality of supports comprises a plurality of support surfaces having at least one polygonal perimeter defining a polyhedron having the substantially spherical structure.

13. The vacuum insulated refrigerator of claim 12, wherein each of the plurality of support surfaces comprises a corresponding aperture of the plurality of apertures.

14. The vacuum insulated refrigerator according to claim 12, wherein the plurality of support surfaces include a first plurality of support surfaces and a second plurality of support surfaces, and wherein each of the first plurality of support surfaces has a first polygonal perimeter among the at least one polygonal perimeter, and further wherein each of the second plurality of support surfaces has a second polygonal perimeter among the at least one polygonal perimeter. 15 . The vacuum insulated refrigerator according to claim 14 , wherein the polyhedron is a truncated icosahedron, and wherein the first polygonal perimeter is a pentagon and the second polygonal perimeter is a hexagon.

16. A method for manufacturing a vacuum insulation cabinet, the method comprising: Provide an outer envelope; positioning at least one liner within said outer envelope to define an insulating cavity therebetween, wherein said at least one liner defines at least one compartment; positioning a plurality of supports within the insulating cavity, wherein each support defines an interior volume and includes a plurality of apertures in fluid communication with the interior volume; coupling a trim partition assembly to the outer envelope and the at least one inner liner to seal the insulating cavity; as well as At least a partial vacuum is drawn within the insulating cavity defined between the outer envelope and the at least one liner.

17. The method of claim 16, wherein the at least one compartment comprises a first compartment and a second compartment, and wherein at least one liner comprises a first liner defining the first compartment and a second liner defining the second compartment, and further wherein the step of positioning the at least one liner within the outer envelope comprises: positioning said first liner within said outer envelope to partially define said insulating cavity therebetween; as well as The second liner is positioned within the outer envelope to partially define the insulation cavity therebetween, wherein the first liner and the second liner partially define a mullion gap within the insulation cavity therebetween.

18. The method of any one of claims 16 or 17, wherein each of the plurality of supports comprises a first support surface and a second support surface, and wherein the step of positioning the plurality of supports within the insulating cavity comprises: positioning the first support surface of each of the plurality of supports to engage an inner surface of the outer envelope; as well as The second support surface of each of the plurality of supports is positioned to engage an inner surface of the at least one liner.

19. The method of any one of claims 16 or 17, wherein the plurality of supports comprises a first plurality of supports and a second plurality of supports, wherein each of the first plurality of supports comprises a first support surface and a second support surface, and the second plurality of supports comprises a third support surface and a fourth support surface, and wherein the step of positioning the plurality of supports within the insulating cavity comprises: positioning the first support surface of each of the first plurality of support members to engage an inner surface of the outer envelope; positioning the third support surface of each of the second plurality of supports to engage the second support surface of the first plurality of supports; as well as The fourth support surface of each support member of the second plurality of supports is positioned to engage an inner surface of the at least one liner.

20. The method of any one of claims 16 or 17, wherein each of the plurality of supports has a diameter that is less than about half of a thickness between an inner surface of the at least one liner and an inner surface of the outer envelope.

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