Insulated panel interface

Abstract

A refrigerator door includes an inner liner defining a first perimeter, an outer wrapper defining a second perimeter that is larger than the first perimeter, the outer wrapper extending along the inner liner, wherein a wrapper flange extends from the outer wrapper along the second perimeter. A trim breaker is coupled to the inner liner proximate the first perimeter and the wrapper flange, the trim breaker defining an outer cavity receiving the wrapper flange. An internal spacer interposes the first and second perimeters and interposes the outer wrapper and the trim breaker. The internal spacer extends between the trim breaker and the outer wrapper and is spaced from the wrapper flange. The trim breaker and the outer wrapper are spaced by the internal spacer such that a gap interposes the outer cavity and a tip of the wrapper flange.

Description

FIELD OF THE DISCLOSURE

[0001] The present disclosure generally relates to an insulated panel, and more specifically, to a vacuum-insulated panel for a refrigerator door.SUMMARY OF THE DISCLOSURE

[0002] According to one aspect of the present disclosure, a refrigerator includes a vacuum insulated door having an inner liner and an outer wrapper extending along the inner liner, wherein the inner liner defines a first perimeter, and wherein the outer wrapper defines a second perimeter, and a trim breaker coupled to the inner liner and the outer wrapper such that the inner liner is not in direct contact with the outer wrapper, the trim breaker defining an inner cavity configured to receive a liner flange extending from the first perimeter and an outer cavity configured to receive a wrapper flange extending from the second perimeter. The refrigerator further defines an internal spacer disposed between the outer wrapper and the trim breaker such that the wrapper flange is in a spaced relationship with the outer cavity, wherein the internal spacer is in contact with a spacer reception surface of the trim breaker, and wherein the internal spacer is a step in the outer wrapper, the step including a first section extending between the outer wrapper and the trim breaker and a second section extending along the spacer reception surface of the trim breaker between the first section and the wrapper flange, wherein the second section is in contact with the trim breaker, and wherein the second section defines the second perimeter.

[0003] According to another aspect of the present disclosure, an insulated panel for a refrigerator includes an inner liner defining a liner flange extending along a first perimeter, an outer wrapper defining a wrapper flange extending along a second perimeter, wherein the first perimeter is smaller than the second perimeter, and wherein the inner liner and the outer wrapper extend along substantially skew planes, and a trim breaker coupled to both the inner liner and the outer wrapper, the trim breaker defining an inner cavity and an outer cavity, wherein the liner flange is disposed in the inner cavity, and wherein the wrapper flange is disposed in the outer cavity. The insulated panel further includes a sealed interior space defined by the inner liner, the outer wrapper, and the trim breaker, wherein the sealed interior space is configured to contain insulative material, and wherein gas molecules have been largely evacuated within the sealed interior space, resulting in a vacuum within the sealed interior space relative to ambient pressure outside of the sealed interior space, and an internal spacer extending between the trim breaker and the outer wrapper such that a gap interposes the wrapper flange and the outer cavity, wherein the wrapper flange is spaced from the internal spacer, wherein the internal spacer is in contact with both the trim breaker and the outer wrapper, and wherein the internal spacer is outside of the outer cavity.

[0004] According to yet another aspect of the present disclosure, a refrigerator door includes an inner liner defining a first perimeter, an outer wrapper defining a second perimeter that is larger than the first perimeter, the outer wrapper extending along the inner liner, wherein a wrapper flange extends from the outer wrapper along the second perimeter, and a trim breaker coupled to the inner liner proximate the first perimeter and the wrapper flange of the outer wrapper, the trim breaker defining an outer cavity receiving the wrapper flange. The refrigerator door further includes an internal spacer interposing the first and second perimeters and interposing the outer wrapper and the trim breaker, wherein the internal spacer extends between the trim breaker and the outer wrapper, wherein the internal spacer is spaced from the wrapper flange, and wherein the trim breaker and the outer wrapper are spaced by the internal spacer such that a gap interposes the outer cavity and a tip of the wrapper flange, the gap being defined in a direction substantially parallel to the wrapper flange.

[0005] A vacuum-insulated panel for a refrigerator door can include an inner liner defining a first perimeter, an outer wrapper defining a second perimeter, and a trim breaker defining an inner cavity and an outer cavity, where the inner cavity is coupled to a liner flange extending from the inner liner along the first perimeter and the outer cavity is coupled to a wrapper flange extending from the outer wrapper along the second perimeter. In a configuration where the wrapper flange is seated within and supported by the outer cavity, variability in the length of the wrapper flange results in undesirable variation in thickness of the vacuum-insulated panel and the refrigerator door. Variation in the thickness of the refrigerator door may create a misalignment between the refrigerator door and a refrigerator cabinet, cause a weaker connection between the wrapper flange and the trim breaker, lead to increased heat transfer through the refrigerator door, and lead to spillage of insulation out of the refrigerator door.

[0006] An interface between the trim breaker and the outer wrapper disclosed herein includes an internal spacer extending between the trim breaker and the outer wrapper, providing alternative support for the outer wrapper and creating a gap interposing the wrapper flange and the outer cavity of the trim breaker. Consequently, the thickness of the insulated panel has an increased consistency despite variances in the length of the wrapper flange. As a result, misalignments between the refrigerator door and a refrigerator cabinet can be reduced, the connection between the wrapper flange and the trim breaker can be improved, consistent parallelism between the door and the cabinet can be achieved, heat transfer through the refrigerator door can be minimized, and insulation spillage out of the refrigerator door can be prevented.

[0007] These and other features, advantages, and objects of the present disclosure will be further understood and appreciated by those skilled in the art by reference to the following specification, claims, and appended drawings.BRIEF DESCRIPTION OF THE DRAWINGS

[0008] In the drawings:

[0009] FIG. 1 is a front perspective view of a refrigerator having a vacuum-insulated cabinet and a vacuum-insulated door pivotally coupled to the vacuum-insulated cabinet;

[0010] FIG. 2 is a partial cross-sectional view of a vacuum-insulated door of the present disclosure, wherein the vacuum-insulated door includes an outer wrapper, an inner liner, and a trim breaker coupled to the outer wrapper and the inner liner, and wherein an internal spacer extends between the outer wrapper and the trim breaker;

[0011] FIG. 3A is a detailed partial cross-sectional view of a vacuum-insulated door of the present disclosure including a distinct internal spacer;

[0012] FIG. 3B is a detailed partial cross-sectional view of a vacuum-insulated door of the present disclosure including an internal spacer that is a protrusion projecting from the trim breaker;

[0013] FIG. 3C is a detailed partial cross-sectional view of a vacuum-insulated door of the present disclosure including an internal spacer defined by a step in the outer wrapper;

[0014] FIG. 4A is a detailed view of the trim breaker coupled to the inner liner, where the internal spacer is a plurality of distinct spacers provided along a spacer reception surface of the trim breaker and defining a plurality of channels;

[0015] FIG. 4B is a detailed view of the trim breaker coupled to the inner liner, where the internal spacer is a protrusion extending along the spacer reception surface of the trim breaker and defining a plurality of channels;

[0016] FIG. 4C is a detailed view of the trim breaker coupled to the inner liner, where the internal spacer is a plurality of transverse ribs provided along the spacer reception surface of the trim breaker and defining a plurality of channels; and

[0017] FIG. 4D is a detailed view of the outer wrapper, where the internal spacer is a step in the outer wrapper extending along the outer perimeter.

[0018] The components in the figures are not necessarily to scale, emphasis instead being placed upon illustrating the principles described herein.DETAILED DESCRIPTION

[0019] The present illustrated embodiments reside primarily in combinations of method steps and apparatus components related to an interface between a wrapper and a trim breaker of an insulated panel for a refrigerator door. Accordingly, the apparatus components and method steps have been represented, where appropriate, by conventional symbols in the drawings, showing only those specific details that are pertinent to understanding the embodiments of the present disclosure so as not to obscure the disclosure with details that will be readily apparent to those of ordinary skill in the art having the benefit of the description herein. Further, like numerals in the description and drawings represent like elements.

[0020] The terms “including,”“comprises,”“comprising,” or any other variation thereof, are intended to cover a non-exclusive inclusion, such that a process, method, article, or apparatus that comprises a list of elements does not include only those elements but may include other elements not expressly listed or inherent to such process, method, article, or apparatus. An element preceded by “comprises a . . . ” does not, without more constraints, preclude the existence of additional identical elements in the process, method, article, or apparatus that comprises the element.

[0021] Referring to FIGS. 1 and 2, reference numeral 10 generally designates a vacuum-insulated refrigerator door. The refrigerator door 10 includes an inner liner 12 defining a first perimeter 14 and an outer wrapper 16 defining a second perimeter 18 that is larger than the first perimeter 14. The outer wrapper 16 extends along the inner liner 12, and a wrapper flange 20 extends from the outer wrapper 16 along the second perimeter 18, the wrapper flange having a length L1. A trim breaker 22 is coupled to the inner liner 12 proximate the first perimeter 14 and the wrapper flange 20 of the outer wrapper 16, the trim breaker 22 defining an outer cavity 24 receiving the wrapper flange 20. An internal spacer 26 is disposed between the first and second perimeters 14, 18. The internal spacer 26 further extends between the trim breaker 22 and the outer wrapper 16. The internal spacer 26 is spaced from the wrapper flange 20, and the trim breaker 22 and the outer wrapper 16 are spaced by the internal spacer 26 such that a gap 28 interposes the outer cavity 24 and a tip 30 of the wrapper flange 20, the gap 28 being defined in a direction substantially parallel to the wrapper flange 20.

[0022] With reference to FIG. 1, a refrigerator 40 includes the door 10 and a cabinet 42. The cabinet 42 includes a plurality of cabinet panels 44. The plurality of cabinet panels 44 defines an external cabinet surface 46, an internal cabinet surface 47 defining an internal compartment 48, and an opening 50 providing access to the internal compartment 48. The cabinet 42 further defines a gasket reception surface 52 extending along the periphery of the opening 50.

[0023] The door 10 is pivotally coupled to the cabinet 42 such that the door 10 can selectively cover the opening 50 of the cabinet 42. The door 10 defines a door perimeter 54, and a gasket 56 is disposed on an internal door surface 58 of the door 10, the gasket 56 extending along the door perimeter 54. When the door 10 covers the opening 50 of the cabinet 42, the gasket 56 is in contact with the cabinet 42 along the gasket reception surface 52, creating an air-tight seal with the gasket reception surface 52. The air-tight seal between the gasket 56 and the gasket reception surface 52 minimizes air ingress into the internal compartment 48 and air egress out of the internal compartment 48, which may reduce contamination of food disposed within the internal compartment 48, temperature loss within the internal compartment 48, and moisture loss within the internal compartment 48, thereby promoting efficiency of the refrigerator 40 and preservation of food disposed within the internal compartment 48.

[0024] With reference to FIGS. 1 and 2, the door 10 of the refrigerator 40 defines the internal door surface 58, an external door surface 60, and an insulated panel 62 disposed between the internal and external door surfaces 58, 60. The internal door surface 58 is spaced from the external door surface 60, defining a door thickness T1. The insulated panel 62 includes the inner liner 12 and the outer wrapper 16 extending along the inner liner 12, where the inner liner 12 extends along the internal door surface 58 and the outer wrapper 16 extends along the external door surface 60. The inner liner 12 is spaced from the outer wrapper 16, defining an insulated panel thickness T2. As illustrated, the door thickness T1 is greater than the insulated panel thickness T2. According to some aspects, the door thickness T1 is a function of the insulated panel thickness T2. Alternatively, the inner liner 12 and the outer wrapper 16 may define the internal and external door surfaces 58, 60, respectively. Accordingly, the door thickness T1 may be the insulated panel thickness T2.

[0025] With reference to FIG. 2, the insulated panel 62 of the door 10 includes the inner liner 12 and the outer wrapper 16, where a liner face 64 of the inner liner 12 and a wrapper face 66 of the outer wrapper 16 extend along substantially skew planes within the door 10. The inner liner 12 defines the first perimeter 14 (hereinafter “inner perimeter”), and the outer wrapper 16 defines the second perimeter 18 (hereinafter “outer perimeter”). The outer perimeter 18 surrounds the inner perimeter 14 while maintaining a spaced relationship with the inner perimeter 14. As illustrated, the wrapper flange 20 extends orthogonally from the wrapper face 66 of the outer wrapper 16 along the outer perimeter 18, and a liner flange 68 extends orthogonally from the liner face 64 of the inner liner 12 along the inner perimeter 14 in the same direction as the wrapper flange 20. Furthermore, the wrapper flange 20 extends from the outer wrapper 16 such that the tip 30 of the wrapper flange 20 is offset from the inner liner 12 in both an X direction and a Y direction. According to some aspects, the wrapper flange 20 and the liner flange 68 may extend from the wrapper face 66 and the liner face 64, respectively, at different angles which may be oblique angles. It is also contemplated that the wrapper flange 20 and / or the liner flange 68 may extend parallel to the wrapper face 66 and the liner face 64.

[0026] The trim breaker 22 is coupled to both the liner flange 68 of the inner liner 12 and the wrapper flange 20 of the outer wrapper 16 along the inner and outer perimeters 14, 18, respectively, the trim breaker 22, the outer wrapper 16, and the inner liner 12 defining an interior space 70. The trim breaker 22 defines an exterior side 80 and an interior side 82 that substantially faces the interior space 70. The interior side 82 of the trim breaker 22 defines the outer cavity 24 proximate the outer perimeter 18 and an inner cavity 84 proximate the inner perimeter 14, where each of the outer and inner cavities 24, 84 are glue grooves configured to adhesively couple to the wrapper flange 20 and the liner flange 68, respectively. The outer cavity 24 is offset from the inner cavity 84 in both the X direction and the Y direction. The exterior side 80 of the trim breaker 22 defines a gasket cavity 86 between the outer and inner cavities 24, 84, where a portion 88 of the trim breaker 22 defining the gasket cavity 86 projects from the interior side 82 of the trim breaker 22. Accordingly, the portion 88 of the trim breaker 22 defines a spacer reception surface 90 projecting from the interior side 82 of the trim breaker 22. The gasket cavity 86 extends along the door perimeter 54, is disposed between the inner perimeter 14 and the outer perimeter 18, and receives an anchor 92 of the gasket 56. The spacer reception surface 90 is in contact with the internal spacer 26, the internal spacer 26 extending between the spacer reception surface 90 and the outer wrapper 16. The internal spacer 26 has a length L2 and maintains a distance equal to the length L2 between the trim breaker 22 and the outer wrapper 16 proximate the internal spacer 26. It is contemplated that the portion 88 of the trim breaker 22 defining the gasket cavity 86 may alternatively define a flat surface, and the gasket 56 may be coupled to the flat surface of the trim breaker 22 without the anchor 92. Additionally or alternatively, the spacer reception surface 90 may be provided in a different location along the interior side 82 of the trim breaker 22 or recessed relative to the spacer reception surface 90 illustrated in FIG. 2.

[0027] With further reference to FIGS. 3A-3C, the outer cavity 24 is defined by a recessed surface 94, a first sidewall 96, and a second sidewall 98. The first and second sidewalls 96, 98 extend along the wrapper flange 20. Furthermore, the first sidewall 96 extends between the recessed surface 94 and a first edge 100 of the outer cavity 24, while the second sidewall 98 extends between the recessed surface 94 and a second edge 102 of the outer cavity 24. The wrapper flange 20 of the outer wrapper 16 is centered between the first and second sidewalls 96, 98 of the outer cavity 24 and, resulting from an interface between the trim breaker 22 and the outer wrapper 16, the tip 30 of the wrapper flange 20 is spaced from the recessed surface 94 of the outer cavity 24 such that the gap 28 interposes the tip 30 and the recessed surface 94. An adhesive material 104 secures the wrapper flange 20 within the outer cavity 24, the adhesive material 104 being disposed between the wrapper flange 20 and each of the pair of sidewalls 96, 98 and between the tip 30 of the wrapper flange 20 and the recessed surface 94 of the outer cavity 24.

[0028] According to some aspects, the first and second sidewalls 96, 98 may be sloped such that the first and second sidewalls 96, 98 proximate the tip 30 of the wrapper flange 20 are closer to the wrapper flange 20 than the first and second sidewalls 96, 98 proximate the first and second edges 100, 102. It is also contemplated that the wrapper flange 20 may be off-centered between the first and second sidewalls 96, 98 of the outer cavity 24 in some instances. The position of the wrapper flange 20 in the X direction (FIG. 2) may be predetermined and / or adjusted during the manufacturing of the door 10 of the refrigerator 40 (FIG. 1). The inner cavity 84 (FIG. 2) of the trim breaker 22 may have a construction that is similar to the outer cavity 24. Additional adhesive material 104 also secures the liner flange 68 of the inner liner 12 within the inner cavity 84. The liner flange 68 may also be in a spaced relationship with the inner cavity 84 in one or more dimensions.

[0029] Referring to FIG. 2, the inner liner 12, the outer wrapper 16, and the trim breaker 22 define the interior space 70 where gas molecules have been largely evacuated, resulting in a vacuum within the interior space 70 relative to ambient pressure exterior to the refrigerator 40 (FIG. 1). The interior space 70 includes a central interior space 106 and a peripheral interior space 108. The internal spacer 26 surrounds the central interior space 106, and the peripheral interior space 108 is defined between the internal spacer 26 and the wrapper flange 20. Specifically, the central interior space 106 is defined by the inner liner 12, the wrapper face 66, the trim breaker 22, and the internal spacer 26. The peripheral interior space 108 is defined by the internal spacer 26, the trim breaker 22, and the wrapper flange 20. In some instances, the peripheral interior space 108 may also be partially defined by the wrapper face 66. The peripheral interior space 108 is in fluid communication with the central interior space 106, and both the central and peripheral interior spaces 106, 108 contain an insulative material 110. Accordingly, during a process in which the central interior space 106 is filled with the insulative material 110, the insulative material 110 passes around or through the internal spacer 26, and the peripheral interior space 108 is filled with the insulative material 110. Alternatively, the peripheral interior space 108 may be filled with the insulative material 110 before the central interior space 106, and the insulative material 110 may pass through one or more channels 109 (FIGS. 4A-4C) and accordingly fill the central interior space 106.

[0030] According to some aspects, the peripheral interior space 108 may be unreachable for the insulative material 110 in the central interior space 106 and may be void of the insulative material 110 or filled separately with additional insulative material 110. In other aspects, the interior space 70 may include the central interior space 106 and not the peripheral interior space 108. The internal spacer 26 may have insulative properties such that the internal spacer 26 provides insulation for the insulated panel 62 in addition to the insulative material 110. Particularly, the internal spacer 26 may be made of a material including but not limited to Expanded Polystyrene (EPS) foam. The internal spacer 26 may additionally be rigid or elastically deformable, for example.

[0031] Referring to FIGS. 3A and 4A, the wrapper flange 20 of the outer wrapper 16 maintains a spaced relationship with the recessed surface 94 and the first and second sidewalls 96, 98 of the outer cavity 24 due to the interface between the outer wrapper 16 and the trim breaker 22. At the interface between the outer wrapper 16 and the trim breaker 22, the internal spacer 26 facilitates coupling of the outer wrapper 16 and the trim breaker 22 such that contact between the trim breaker 22 and the outer wrapper 16 is indirect. As illustrated, the internal spacer 26 includes a distinct spacer 112. The distinct spacer 112 includes an elongate segment 114 extending substantially orthogonally between a first base 116 of the distinct spacer 112 and a second base 118 of the distinct spacer 112, defining an I-shaped cross-section, where the first and second bases 116, 118 of the distinct spacer 112 are wider than the elongate segment 114. The first base 116 extends along the spacer reception surface 90 of the trim breaker 22 adjacent to the outer cavity 24, and the second base 118 extends along the wrapper face 66 of the outer wrapper 16 adjacent to the wrapper flange 20. The distinct spacer 112 defines the length L2, spacing the wrapper face 66 and the spacer reception surface 90 such that the gap 28 interposes the tip 30 of the wrapper flange 20 and the recessed surface 94 of the outer cavity 24 of the trim breaker 22.

[0032] According to some aspects, the internal spacer 26 includes a plurality of separated distinct spacers 112 extending between the trim breaker 22 and the outer wrapper 16 along the outer perimeter 18. In such aspects, the first and second bases 116, 118 may have a circular or other geometric shape. In one exemplary configuration, one distinct spacer 112 may be situated at each corner 120 of the door 10 of the refrigerator 40 (FIG. 1), and distinct spacers 112 may additionally interpose the corners 120 of the door 10. In another exemplary configuration, a plurality of separated distinct spacers 112 may be situated along the outer perimeter 18 and spaced apart by a distance of one to ten millimeters. Additionally or alternatively, one distinct spacer 112 may extend between the trim breaker 22 and the outer wrapper 16, the one distinct spacer 112 extending partially or entirely along the outer perimeter 18. In configurations where the distinct spacer 112 extends along the entirety of the outer perimeter 18, the internal spacer 26 may define one or more channels 109 such that the central interior space 106 is in fluid communication with the peripheral interior space 108. Accordingly, during a process in which the central interior space 106 is filled with the insulative material 110, the insulative material 110 can pass through the one or more channels 109 and fill the peripheral interior space 108.

[0033] Referring to FIGS. 2, 3A, and 4A, the first and second bases 116, 118 of the illustrated distinct spacer 112 assist with achieving an improved connection between the outer wrapper 16 and the trim breaker 22 and a more convenient assembly of the door 10 of the refrigerator 40 (FIG. 1) as compared to known refrigerator doors. In an exemplary manufacturing process of the door 10 having a plurality of distinct spacers 112, the liner flange 68 of the inner liner 12 may be adhesively coupled to the trim breaker 22 within the inner cavity 84, and the first base 116 of each distinct spacer 112 may be adhesively coupled to the spacer reception surface 90 of the trim breaker 22. The outer wrapper 16 may then be placed over the inner liner 12 and the trim breaker 22 such that the wrapper face 66 abuts the second base 118 of each distinct spacer 112 and the wrapper flange 20 is received by the outer cavity 24, thereby creating the gap 28 between the tip 30 of the wrapper flange 20 and the recessed surface 94 of the outer cavity 24. Thereafter, the adhesive material 104 may be placed or injected into the gap 28 in the outer cavity 24 and around the wrapper flange 20. The addition of the adhesive materials 104 into the inner cavity 84 and the outer cavity 24 around the liner flange 68 and the wrapper flange 20, respectively, creates a hermetic seal that enables the vacuum sealing of the interior space 70. According to some aspects, the inner liner 12 and the trim breaker 22 may be placed over the outer wrapper 16 as opposed to the outer wrapper 16 being placed over the inner liner 12 and the trim breaker 22. According to yet another aspect, the outer wrapper 16 may be coupled to the trim breaker 22 before the inner liner 12 is coupled to the trim breaker 22 during an exemplary manufacturing process.

[0034] In some instances, the second base 118 of each distinct spacer 112 provided in the door 10 of the refrigerator 40 (FIG. 1) may be adhesively coupled to the wrapper face 66 of the outer wrapper 16, and the inner liner 12 and the trim breaker 22 may be placed over the outer wrapper 16 during assembly such that the spacer reception surface 90 of the trim breaker 22 abuts the first base 116 of each distinct spacer 112 and the wrapper flange 20 is received by the outer cavity 24. Each distinct spacer 112 may alternatively be placed onto the wrapper face 66 or the spacer reception surface 90 in an exemplary manufacturing process as opposed to being adhesively coupled to the wrapper face 66 or the spacer reception surface 90. Alternatively, both the first and second bases 116, 118 may be adhesively coupled to the spacer reception surface 90 of the trim breaker 22 and the wrapper face 66 of the outer wrapper 16, respectively, during an exemplary manufacturing process.

[0035] With reference now to FIGS. 3B and 4B, the internal spacer 26 may be a protrusion 122 projecting substantially orthogonally from the spacer reception surface 90 of the trim breaker 22 toward the wrapper face 66 of the outer wrapper 16. The protrusion 122 is in contact with the wrapper face 66 and is spaced from the wrapper flange 20 such that the wrapper flange 20, the interior side 82 of the trim breaker 22, and the protrusion 122 at least partially define the peripheral interior space 108. The protrusion 122 defines a width W that may vary between configurations. The protrusion 122 defines the length L2 and is tapered such that the width W of the protrusion 122 proximate the trim breaker 22 is greater than the width W of the protrusion 122 proximate the wrapper face 66. The taper of the protrusion 122 may vary between configurations. For example, the width W of the protrusion 122 proximate the wrapper face 66 may be substantially trivial in some configurations. Additionally or alternatively, the width W of the protrusion 122 proximate the spacer reception surface 90 may span the spacer reception surface 90. In other configurations, the protrusion 122 may be tapered such that the width W of the protrusion 122 proximate the wrapper face 66 is greater than the width W of the protrusion 122 proximate the trim breaker 22. The protrusion 122 may alternatively have no taper.

[0036] The protrusion 122 of the trim breaker 22 defines a terminal point 124 which may be squared or rounded, for example. In instances where the terminal point 124 of the protrusion 122 is adhered to the wrapper face 66 of the outer wrapper 16 during the manufacturing of the insulated panel 62, better adhesion between the protrusion 122 and the wrapper face 66 may be achieved when the terminal point 124 is wider and squared. Alternatively, less material may be used to construct the protrusion 122 having a narrower, rounded terminal point 124, which may reduce cost. It is also contemplated that the protrusion 122 may define one or more channels 109, which may be one or more apertures, extending transversely through the protrusion 122. Accordingly, the central and peripheral interior spaces 106, 108 may be in fluid communication via the one or more channels 109, and the insulative material 110 placed or injected into the central interior space 106 may pass through the one or more channels 109 and fill the peripheral interior space 108. In one nonlimiting example, the protrusion 122 defines one or more channels 109 spaced along the outer perimeter 18 such that the protrusion 122 forms a plurality of transverse ribs 125 (FIG. 4C) extending along the wrapper face 66 in a direction perpendicular to the wrapper flange 20. Here, the one or more channels 109 may be spaced apart by a distance of one to ten millimeters, for example.

[0037] With reference now to FIGS. 3C and 4D, the internal spacer 26 is a step 126 in the outer wrapper 16 along the outer perimeter 18 adjacent to the wrapper flange 20. The step 126 includes a first section 128 extending substantially orthogonally from the wrapper face 66 toward the spacer reception surface 90 of the trim breaker 22. The first section 128 further extends between a first end 130 and a second end 132, wherein the first end 130 is connected to the wrapper face 66 and the second end 132 is proximate the spacer reception surface 90 of the trim breaker 22. In some instances, the second end 132 of the first section 128 may abut the spacer reception surface 90. The step 126 further includes a second section 134 extending substantially orthogonally from the first section 128. The second section 134 further extends between a third end 136 and a fourth end 138, where the third end 136 is connected to the second end 132 of the first section 128 and the fourth end 138 is connected to the wrapper flange 20. The second section 134 is in contact with the spacer reception surface 90, and the wrapper flange 20 extends substantially orthogonally from the fourth end 138 of the second section 134. Furthermore, the first section 128 defines a first section length SL1, which may be the length L2 of the internal spacer 26.

[0038] The wrapper flange 20 of the outer wrapper 16 is spaced from the first section 128 of the step 126 by a distance equal to a second section length SL2 of the second section 134, and the wrapper flange 20 extends from the second section 134 such that the wrapper flange 20 is centered between the first and second sidewalls 96, 98 of the outer cavity 24 and the gap 28 interposes the tip 30 of the wrapper flange 20 and the recessed surface 94 of the outer cavity 24. The intersections of the wrapper face 66 and the first section 128, the first section 128 and the second section 134, and the second section 134 and the wrapper flange 20 are beveled, but such intersections may be pointed in other instances. As illustrated in FIG. 3C, the step 126, the trim breaker 22, and the outer wrapper 16 define the central interior space 106. In some instances, additional insulative material 110 may be disposed within a pocket 140 defined at least partially by the outer wrapper 16, the trim breaker 22, and the exterior door wall to improve insulative properties of the door 10 of the refrigerator 40 (FIG. 1). The pocket 140 may be filled with additional insulative material 110 separate from the insulative material 110 in the central interior space 106. Alternatively, the pocket 140 may be filled with the insulative material 110 through one or more channels 109 (FIGS. 4A-4C) defined by the step 126 of the outer wrapper 16 and / or the wrapper face 66 of the outer wrapper 16 such that the pocket 140 and the central interior space 106 are in fluid communication. Accordingly, when the central interior space 106 is filled with the insulative material 110, the pocket 140 may also be filled with the insulative material 110. Moreover, the pocket 140 may also be vacuum sealed and define a vacuum therein.

[0039] Referring to FIGS. 1 and 2, it is contemplated that the insulated panel 62 may additionally or alternatively be integrated into the cabinet 42 of the refrigerator 40. For example, the insulated panel 62 may extend between the external cabinet surface 46 of the cabinet 42 and the internal cabinet surface 47 of the internal compartment 48 of the cabinet 42. The insulated panel 62 may further define the external cabinet surface 46 of the cabinet 42 and the internal cabinet surface 47 of the internal compartment 48. In another example, the refrigerator 40 may include a plurality of insulated panels 62, wherein each of the plurality of insulated panels 62 is disposed within one of the plurality of cabinet panels 44.

[0040] With reference to FIGS. 1-3C, in instances where the gap 28 is not provided between the outer wrapper 16 and the recessed surface 94 of the outer cavity 24 of the trim breaker 22, variation in the length L1 of the wrapper flange 20 may result due to the manufacturing of the outer wrapper 16, which in turn can cause a variation in thickness T2 of the insulated panel 62 and thickness T1 of the door 10 of the refrigerator 40. The interface between the trim breaker 22 and the outer wrapper 16 disclosed herein advantageously includes the internal spacer 26 extending between the trim breaker 22 and the outer wrapper 16 within the outer perimeter 18, thereby separating the trim breaker 22 and the outer wrapper 16 such that the gap 28 interposes the tip 30 of the wrapper flange 20 and the recessed surface 94 of the outer cavity 24. The gap 28 allows for a variance in the length L1 of the wrapper flange 20, providing the insulated panel 62 and the door 10 of the refrigerator 40 with a decreased thickness variability. The gap 28 also allows for the convenient placement or injection of the adhesive material 104 in the outer cavity 24 between the wrapper flange 20 and each of the first and second sidewalls 96, 98 and between the tip 30 of the wrapper flange 20 and the recessed surface 94, which may result in improved adhesion between the wrapper flange 20 and the trim breaker 22 and therefore improved durability of the insulated panel 62 and the door 10 of the refrigerator 40.

[0041] It will be understood by one having ordinary skill in the art that construction of the described disclosure and other components is not limited to any specific material. Other exemplary embodiments of the disclosure disclosed herein may be formed from a wide variety of materials, unless described otherwise herein.

[0042] According to one aspect of the present disclosure, a refrigerator includes a vacuum insulated door having an inner liner and an outer wrapper extending along the inner liner, wherein the inner liner defines a first perimeter, and wherein the outer wrapper defines a second perimeter, and a trim breaker coupled to the inner liner and the outer wrapper such that the inner liner is not in direct contact with the outer wrapper, the trim breaker defining an inner cavity configured to receive a liner flange extending from the first perimeter and an outer cavity configured to receive a wrapper flange extending from the second perimeter. The refrigerator further defines an internal spacer disposed between the outer wrapper and the trim breaker such that the wrapper flange is in a spaced relationship with the outer cavity, wherein the internal spacer is in contact with a spacer reception surface of the trim breaker, and wherein the internal spacer is a step in the outer wrapper, the step including a first section extending between the outer wrapper and the trim breaker and a second section extending along the spacer reception surface of the trim breaker between the first section and the wrapper flange, wherein the second section is in contact with the trim breaker, and wherein the second section defines the second perimeter.

[0043] According to another aspect, the liner and wrapper flanges extend along the first and second perimeters, respectively.

[0044] According to yet another aspect, the liner and wrapper flanges extend from the inner liner and the outer wrapper, respectively, in the same direction.

[0045] According to still yet another aspect, the internal spacer extends along the second perimeter.

[0046] According to yet another aspect, the first section extends between the trim breaker and the outer wrapper in a direction substantially parallel to the liner and wrapper flanges.

[0047] According to another aspect, the internal spacer defines the second perimeter.

[0048] According to yet another aspect, a tip of the wrapper flange is spaced from the outer cavity in a direction substantially parallel to the wrapper flange.

[0049] According to still yet another aspect, the wrapper flange is offset from the liner flange in at least two directions.

[0050] According to yet another aspect, an adhesive material is received by the inner and outer cavities such that the inner liner, the outer wrapper, and the trim breaker define a sealed interior space, and wherein the sealed interior space has a pressure that is substantially less than the pressure exterior to the vacuum insulated door.

[0051] According to another aspect of the present disclosure, an insulated panel for a refrigerator includes an inner liner defining a liner flange extending along a first perimeter, an outer wrapper defining a wrapper flange extending along a second perimeter, wherein the first perimeter is smaller than the second perimeter, and wherein the inner liner and the outer wrapper extend along substantially skew planes, and a trim breaker coupled to both the inner liner and the outer wrapper, the trim breaker defining an inner cavity and an outer cavity, wherein the liner flange is disposed in the inner cavity, and wherein the wrapper flange is disposed in the outer cavity. The insulated panel further includes a sealed interior space defined by the inner liner, the outer wrapper, and the trim breaker, wherein the sealed interior space is configured to contain insulative material, and wherein gas molecules have been largely evacuated within the sealed interior space, resulting in a vacuum within the sealed interior space relative to ambient pressure outside of the sealed interior space, and an internal spacer extending between the trim breaker and the outer wrapper such that a gap interposes the wrapper flange and the outer cavity, wherein the wrapper flange is spaced from the internal spacer, wherein the internal spacer is in contact with both the trim breaker and the outer wrapper, and wherein the internal spacer is outside of the outer cavity.

[0052] According to another aspect, the internal spacer protrudes from the trim breaker proximate the outer cavity.

[0053] According to yet another aspect, the internal spacer is tapered toward the outer wrapper.

[0054] According to still yet another aspect, the internal spacer defines one or more channels extending transversely through the internal spacer.

[0055] According to yet another aspect, the sealed interior space includes a central interior space and a peripheral interior space, wherein the central interior space is defined by the internal spacer, the trim breaker, the inner liner, and the outer wrapper, wherein the peripheral interior space is defined by the internal spacer, the wrapper flange, and the trim breaker, and wherein the peripheral interior space is in fluid communication with the central interior space through the one or more channels.

[0056] According to another aspect, the outer cavity defines a pair of sidewalls and a recessed surface extending between the pair of sidewalls, wherein the wrapper flange is spaced from the recessed surface and each of the pair of sidewalls, and wherein an adhesive material is disposed between the wrapper flange and the recessed surface and between the wrapper flange and each of the pair of sidewalls.

[0057] According to another aspect of the present disclosure, a refrigerator door includes an inner liner defining a first perimeter, an outer wrapper defining a second perimeter that is larger than the first perimeter, the outer wrapper extending along the inner liner, wherein a wrapper flange extends from the outer wrapper along the second perimeter, and a trim breaker coupled to the inner liner proximate the first perimeter and the wrapper flange of the outer wrapper, the trim breaker defining an outer cavity receiving the wrapper flange. The refrigerator door further includes an internal spacer disposed between the first and second perimeters and extending between the trim breaker and the outer wrapper, wherein the internal spacer is spaced from the wrapper flange, and wherein the trim breaker and the outer wrapper are spaced by the internal spacer such that a gap interposes the outer cavity and a tip of the wrapper flange, the gap being defined in a direction substantially parallel to the wrapper flange.

[0058] According to another aspect, the internal spacer is tapered toward the outer wrapper and protrudes from the trim breaker.

[0059] According to yet another aspect, the internal spacer defines one or more channels.

[0060] According to still yet another aspect, the internal spacer surrounds a central interior space, wherein the central interior space is vacuum sealed and contains insulative material.

[0061] According to yet another aspect, a peripheral interior space is defined between the internal spacer and the wrapper flange, wherein the peripheral interior space is vacuum sealed and contains insulative material.

[0062] For purposes of this disclosure, the term “coupled” (in all of its forms, couple, coupling, coupled, etc.) generally means the joining of two components (electrical or mechanical) directly or indirectly to one another. Such joining may be stationary in nature or movable in nature. Such joining may be achieved with the two components (electrical or mechanical) and any additional intermediate members being integrally formed as a single unitary body with one another or with the two components. Such joining may be permanent in nature or may be removable or releasable in nature unless otherwise stated.

[0063] It is also important to note that the construction and arrangement of the elements of the disclosure as shown in the exemplary embodiments is illustrative only. Although only a few embodiments of the present innovations have been described in detail in this disclosure, those skilled in the art who review this disclosure will readily appreciate that many modifications are possible (e.g., variations in sizes, dimensions, structures, shapes and proportions of the various elements, values of parameters, mounting arrangements, use of materials, colors, orientations, etc.) without materially departing from the novel teachings and advantages of the subject matter recited. For example, elements shown as integrally formed may be constructed of multiple parts or elements shown as multiple parts may be integrally formed, the operation of the interfaces may be reversed or otherwise varied, the length or width of the structures and / or members or connector or other elements of the system may be varied, the nature or number of adjustment positions provided between the elements may be varied. It should be noted that the elements and / or assemblies of the system may be constructed from any of a wide variety of materials that provide sufficient strength or durability, in any of a wide variety of colors, textures, and combinations. Accordingly, all such modifications are intended to be included within the scope of the present innovations. Other substitutions, modifications, changes, and omissions may be made in the design, operating conditions, and arrangement of the desired and other exemplary embodiments without departing from the spirit of the present innovations.

[0064] It will be understood that any described processes or steps within described processes may 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 are not to be construed as limiting.

Examples

Embodiment Construction

[0019]The present illustrated embodiments reside primarily in combinations of method steps and apparatus components related to an interface between a wrapper and a trim breaker of an insulated panel for a refrigerator door. Accordingly, the apparatus components and method steps have been represented, where appropriate, by conventional symbols in the drawings, showing only those specific details that are pertinent to understanding the embodiments of the present disclosure so as not to obscure the disclosure with details that will be readily apparent to those of ordinary skill in the art having the benefit of the description herein. Further, like numerals in the description and drawings represent like elements.

[0020]The terms “including,”“comprises,”“comprising,” or any other variation thereof, are intended to cover a non-exclusive inclusion, such that a process, method, article, or apparatus that comprises a list of elements does not include only those elements but may include other ...

FIELD OF THE DISCLOSURE

[0001] The present disclosure generally relates to an insulated panel, and more specifically, to a vacuum-insulated panel for a refrigerator door.SUMMARY OF THE DISCLOSURE

[0002] According to one aspect of the present disclosure, a refrigerator includes a vacuum insulated door having an inner liner and an outer wrapper extending along the inner liner, wherein the inner liner defines a first perimeter, and wherein the outer wrapper defines a second perimeter, and a trim breaker coupled to the inner liner and the outer wrapper such that the inner liner is not in direct contact with the outer wrapper, the trim breaker defining an inner cavity configured to receive a liner flange extending from the first perimeter and an outer cavity configured to receive a wrapper flange extending from the second perimeter. The refrigerator further defines an internal spacer disposed between the outer wrapper and the trim breaker such that the wrapper flange is in a spaced relationship with the outer cavity, wherein the internal spacer is in contact with a spacer reception surface of the trim breaker, and wherein the internal spacer is a step in the outer wrapper, the step including a first section extending between the outer wrapper and the trim breaker and a second section extending along the spacer reception surface of the trim breaker between the first section and the wrapper flange, wherein the second section is in contact with the trim breaker, and wherein the second section defines the second perimeter.

[0003] According to another aspect of the present disclosure, an insulated panel for a refrigerator includes an inner liner defining a liner flange extending along a first perimeter, an outer wrapper defining a wrapper flange extending along a second perimeter, wherein the first perimeter is smaller than the second perimeter, and wherein the inner liner and the outer wrapper extend along substantially skew planes, and a trim breaker coupled to both the inner liner and the outer wrapper, the trim breaker defining an inner cavity and an outer cavity, wherein the liner flange is disposed in the inner cavity, and wherein the wrapper flange is disposed in the outer cavity. The insulated panel further includes a sealed interior space defined by the inner liner, the outer wrapper, and the trim breaker, wherein the sealed interior space is configured to contain insulative material, and wherein gas molecules have been largely evacuated within the sealed interior space, resulting in a vacuum within the sealed interior space relative to ambient pressure outside of the sealed interior space, and an internal spacer extending between the trim breaker and the outer wrapper such that a gap interposes the wrapper flange and the outer cavity, wherein the wrapper flange is spaced from the internal spacer, wherein the internal spacer is in contact with both the trim breaker and the outer wrapper, and wherein the internal spacer is outside of the outer cavity.

[0004] According to yet another aspect of the present disclosure, a refrigerator door includes an inner liner defining a first perimeter, an outer wrapper defining a second perimeter that is larger than the first perimeter, the outer wrapper extending along the inner liner, wherein a wrapper flange extends from the outer wrapper along the second perimeter, and a trim breaker coupled to the inner liner proximate the first perimeter and the wrapper flange of the outer wrapper, the trim breaker defining an outer cavity receiving the wrapper flange. The refrigerator door further includes an internal spacer interposing the first and second perimeters and interposing the outer wrapper and the trim breaker, wherein the internal spacer extends between the trim breaker and the outer wrapper, wherein the internal spacer is spaced from the wrapper flange, and wherein the trim breaker and the outer wrapper are spaced by the internal spacer such that a gap interposes the outer cavity and a tip of the wrapper flange, the gap being defined in a direction substantially parallel to the wrapper flange.

[0005] A vacuum-insulated panel for a refrigerator door can include an inner liner defining a first perimeter, an outer wrapper defining a second perimeter, and a trim breaker defining an inner cavity and an outer cavity, where the inner cavity is coupled to a liner flange extending from the inner liner along the first perimeter and the outer cavity is coupled to a wrapper flange extending from the outer wrapper along the second perimeter. In a configuration where the wrapper flange is seated within and supported by the outer cavity, variability in the length of the wrapper flange results in undesirable variation in thickness of the vacuum-insulated panel and the refrigerator door. Variation in the thickness of the refrigerator door may create a misalignment between the refrigerator door and a refrigerator cabinet, cause a weaker connection between the wrapper flange and the trim breaker, lead to increased heat transfer through the refrigerator door, and lead to spillage of insulation out of the refrigerator door.

[0006] An interface between the trim breaker and the outer wrapper disclosed herein includes an internal spacer extending between the trim breaker and the outer wrapper, providing alternative support for the outer wrapper and creating a gap interposing the wrapper flange and the outer cavity of the trim breaker. Consequently, the thickness of the insulated panel has an increased consistency despite variances in the length of the wrapper flange. As a result, misalignments between the refrigerator door and a refrigerator cabinet can be reduced, the connection between the wrapper flange and the trim breaker can be improved, consistent parallelism between the door and the cabinet can be achieved, heat transfer through the refrigerator door can be minimized, and insulation spillage out of the refrigerator door can be prevented.

[0007] These and other features, advantages, and objects of the present disclosure will be further understood and appreciated by those skilled in the art by reference to the following specification, claims, and appended drawings.BRIEF DESCRIPTION OF THE DRAWINGS

[0008] In the drawings:

[0009] FIG. 1 is a front perspective view of a refrigerator having a vacuum-insulated cabinet and a vacuum-insulated door pivotally coupled to the vacuum-insulated cabinet;

[0010] FIG. 2 is a partial cross-sectional view of a vacuum-insulated door of the present disclosure, wherein the vacuum-insulated door includes an outer wrapper, an inner liner, and a trim breaker coupled to the outer wrapper and the inner liner, and wherein an internal spacer extends between the outer wrapper and the trim breaker;

[0011] FIG. 3A is a detailed partial cross-sectional view of a vacuum-insulated door of the present disclosure including a distinct internal spacer;

[0012] FIG. 3B is a detailed partial cross-sectional view of a vacuum-insulated door of the present disclosure including an internal spacer that is a protrusion projecting from the trim breaker;

[0013] FIG. 3C is a detailed partial cross-sectional view of a vacuum-insulated door of the present disclosure including an internal spacer defined by a step in the outer wrapper;

[0014] FIG. 4A is a detailed view of the trim breaker coupled to the inner liner, where the internal spacer is a plurality of distinct spacers provided along a spacer reception surface of the trim breaker and defining a plurality of channels;

[0015] FIG. 4B is a detailed view of the trim breaker coupled to the inner liner, where the internal spacer is a protrusion extending along the spacer reception surface of the trim breaker and defining a plurality of channels;

[0016] FIG. 4C is a detailed view of the trim breaker coupled to the inner liner, where the internal spacer is a plurality of transverse ribs provided along the spacer reception surface of the trim breaker and defining a plurality of channels; and

[0017] FIG. 4D is a detailed view of the outer wrapper, where the internal spacer is a step in the outer wrapper extending along the outer perimeter.

[0018] The components in the figures are not necessarily to scale, emphasis instead being placed upon illustrating the principles described herein.DETAILED DESCRIPTION

[0019] The present illustrated embodiments reside primarily in combinations of method steps and apparatus components related to an interface between a wrapper and a trim breaker of an insulated panel for a refrigerator door. Accordingly, the apparatus components and method steps have been represented, where appropriate, by conventional symbols in the drawings, showing only those specific details that are pertinent to understanding the embodiments of the present disclosure so as not to obscure the disclosure with details that will be readily apparent to those of ordinary skill in the art having the benefit of the description herein. Further, like numerals in the description and drawings represent like elements.

[0020] The terms “including,”“comprises,”“comprising,” or any other variation thereof, are intended to cover a non-exclusive inclusion, such that a process, method, article, or apparatus that comprises a list of elements does not include only those elements but may include other elements not expressly listed or inherent to such process, method, article, or apparatus. An element preceded by “comprises a . . . ” does not, without more constraints, preclude the existence of additional identical elements in the process, method, article, or apparatus that comprises the element.

[0021] Referring to FIGS. 1 and 2, reference numeral 10 generally designates a vacuum-insulated refrigerator door. The refrigerator door 10 includes an inner liner 12 defining a first perimeter 14 and an outer wrapper 16 defining a second perimeter 18 that is larger than the first perimeter 14. The outer wrapper 16 extends along the inner liner 12, and a wrapper flange 20 extends from the outer wrapper 16 along the second perimeter 18, the wrapper flange having a length L1. A trim breaker 22 is coupled to the inner liner 12 proximate the first perimeter 14 and the wrapper flange 20 of the outer wrapper 16, the trim breaker 22 defining an outer cavity 24 receiving the wrapper flange 20. An internal spacer 26 is disposed between the first and second perimeters 14, 18. The internal spacer 26 further extends between the trim breaker 22 and the outer wrapper 16. The internal spacer 26 is spaced from the wrapper flange 20, and the trim breaker 22 and the outer wrapper 16 are spaced by the internal spacer 26 such that a gap 28 interposes the outer cavity 24 and a tip 30 of the wrapper flange 20, the gap 28 being defined in a direction substantially parallel to the wrapper flange 20.

[0022] With reference to FIG. 1, a refrigerator 40 includes the door 10 and a cabinet 42. The cabinet 42 includes a plurality of cabinet panels 44. The plurality of cabinet panels 44 defines an external cabinet surface 46, an internal cabinet surface 47 defining an internal compartment 48, and an opening 50 providing access to the internal compartment 48. The cabinet 42 further defines a gasket reception surface 52 extending along the periphery of the opening 50.

[0023] The door 10 is pivotally coupled to the cabinet 42 such that the door 10 can selectively cover the opening 50 of the cabinet 42. The door 10 defines a door perimeter 54, and a gasket 56 is disposed on an internal door surface 58 of the door 10, the gasket 56 extending along the door perimeter 54. When the door 10 covers the opening 50 of the cabinet 42, the gasket 56 is in contact with the cabinet 42 along the gasket reception surface 52, creating an air-tight seal with the gasket reception surface 52. The air-tight seal between the gasket 56 and the gasket reception surface 52 minimizes air ingress into the internal compartment 48 and air egress out of the internal compartment 48, which may reduce contamination of food disposed within the internal compartment 48, temperature loss within the internal compartment 48, and moisture loss within the internal compartment 48, thereby promoting efficiency of the refrigerator 40 and preservation of food disposed within the internal compartment 48.

[0024] With reference to FIGS. 1 and 2, the door 10 of the refrigerator 40 defines the internal door surface 58, an external door surface 60, and an insulated panel 62 disposed between the internal and external door surfaces 58, 60. The internal door surface 58 is spaced from the external door surface 60, defining a door thickness T1. The insulated panel 62 includes the inner liner 12 and the outer wrapper 16 extending along the inner liner 12, where the inner liner 12 extends along the internal door surface 58 and the outer wrapper 16 extends along the external door surface 60. The inner liner 12 is spaced from the outer wrapper 16, defining an insulated panel thickness T2. As illustrated, the door thickness T1 is greater than the insulated panel thickness T2. According to some aspects, the door thickness T1 is a function of the insulated panel thickness T2. Alternatively, the inner liner 12 and the outer wrapper 16 may define the internal and external door surfaces 58, 60, respectively. Accordingly, the door thickness T1 may be the insulated panel thickness T2.

[0025] With reference to FIG. 2, the insulated panel 62 of the door 10 includes the inner liner 12 and the outer wrapper 16, where a liner face 64 of the inner liner 12 and a wrapper face 66 of the outer wrapper 16 extend along substantially skew planes within the door 10. The inner liner 12 defines the first perimeter 14 (hereinafter “inner perimeter”), and the outer wrapper 16 defines the second perimeter 18 (hereinafter “outer perimeter”). The outer perimeter 18 surrounds the inner perimeter 14 while maintaining a spaced relationship with the inner perimeter 14. As illustrated, the wrapper flange 20 extends orthogonally from the wrapper face 66 of the outer wrapper 16 along the outer perimeter 18, and a liner flange 68 extends orthogonally from the liner face 64 of the inner liner 12 along the inner perimeter 14 in the same direction as the wrapper flange 20. Furthermore, the wrapper flange 20 extends from the outer wrapper 16 such that the tip 30 of the wrapper flange 20 is offset from the inner liner 12 in both an X direction and a Y direction. According to some aspects, the wrapper flange 20 and the liner flange 68 may extend from the wrapper face 66 and the liner face 64, respectively, at different angles which may be oblique angles. It is also contemplated that the wrapper flange 20 and / or the liner flange 68 may extend parallel to the wrapper face 66 and the liner face 64.

[0026] The trim breaker 22 is coupled to both the liner flange 68 of the inner liner 12 and the wrapper flange 20 of the outer wrapper 16 along the inner and outer perimeters 14, 18, respectively, the trim breaker 22, the outer wrapper 16, and the inner liner 12 defining an interior space 70. The trim breaker 22 defines an exterior side 80 and an interior side 82 that substantially faces the interior space 70. The interior side 82 of the trim breaker 22 defines the outer cavity 24 proximate the outer perimeter 18 and an inner cavity 84 proximate the inner perimeter 14, where each of the outer and inner cavities 24, 84 are glue grooves configured to adhesively couple to the wrapper flange 20 and the liner flange 68, respectively. The outer cavity 24 is offset from the inner cavity 84 in both the X direction and the Y direction. The exterior side 80 of the trim breaker 22 defines a gasket cavity 86 between the outer and inner cavities 24, 84, where a portion 88 of the trim breaker 22 defining the gasket cavity 86 projects from the interior side 82 of the trim breaker 22. Accordingly, the portion 88 of the trim breaker 22 defines a spacer reception surface 90 projecting from the interior side 82 of the trim breaker 22. The gasket cavity 86 extends along the door perimeter 54, is disposed between the inner perimeter 14 and the outer perimeter 18, and receives an anchor 92 of the gasket 56. The spacer reception surface 90 is in contact with the internal spacer 26, the internal spacer 26 extending between the spacer reception surface 90 and the outer wrapper 16. The internal spacer 26 has a length L2 and maintains a distance equal to the length L2 between the trim breaker 22 and the outer wrapper 16 proximate the internal spacer 26. It is contemplated that the portion 88 of the trim breaker 22 defining the gasket cavity 86 may alternatively define a flat surface, and the gasket 56 may be coupled to the flat surface of the trim breaker 22 without the anchor 92. Additionally or alternatively, the spacer reception surface 90 may be provided in a different location along the interior side 82 of the trim breaker 22 or recessed relative to the spacer reception surface 90 illustrated in FIG. 2.

[0027] With further reference to FIGS. 3A-3C, the outer cavity 24 is defined by a recessed surface 94, a first sidewall 96, and a second sidewall 98. The first and second sidewalls 96, 98 extend along the wrapper flange 20. Furthermore, the first sidewall 96 extends between the recessed surface 94 and a first edge 100 of the outer cavity 24, while the second sidewall 98 extends between the recessed surface 94 and a second edge 102 of the outer cavity 24. The wrapper flange 20 of the outer wrapper 16 is centered between the first and second sidewalls 96, 98 of the outer cavity 24 and, resulting from an interface between the trim breaker 22 and the outer wrapper 16, the tip 30 of the wrapper flange 20 is spaced from the recessed surface 94 of the outer cavity 24 such that the gap 28 interposes the tip 30 and the recessed surface 94. An adhesive material 104 secures the wrapper flange 20 within the outer cavity 24, the adhesive material 104 being disposed between the wrapper flange 20 and each of the pair of sidewalls 96, 98 and between the tip 30 of the wrapper flange 20 and the recessed surface 94 of the outer cavity 24.

[0028] According to some aspects, the first and second sidewalls 96, 98 may be sloped such that the first and second sidewalls 96, 98 proximate the tip 30 of the wrapper flange 20 are closer to the wrapper flange 20 than the first and second sidewalls 96, 98 proximate the first and second edges 100, 102. It is also contemplated that the wrapper flange 20 may be off-centered between the first and second sidewalls 96, 98 of the outer cavity 24 in some instances. The position of the wrapper flange 20 in the X direction (FIG. 2) may be predetermined and / or adjusted during the manufacturing of the door 10 of the refrigerator 40 (FIG. 1). The inner cavity 84 (FIG. 2) of the trim breaker 22 may have a construction that is similar to the outer cavity 24. Additional adhesive material 104 also secures the liner flange 68 of the inner liner 12 within the inner cavity 84. The liner flange 68 may also be in a spaced relationship with the inner cavity 84 in one or more dimensions.

[0029] Referring to FIG. 2, the inner liner 12, the outer wrapper 16, and the trim breaker 22 define the interior space 70 where gas molecules have been largely evacuated, resulting in a vacuum within the interior space 70 relative to ambient pressure exterior to the refrigerator 40 (FIG. 1). The interior space 70 includes a central interior space 106 and a peripheral interior space 108. The internal spacer 26 surrounds the central interior space 106, and the peripheral interior space 108 is defined between the internal spacer 26 and the wrapper flange 20. Specifically, the central interior space 106 is defined by the inner liner 12, the wrapper face 66, the trim breaker 22, and the internal spacer 26. The peripheral interior space 108 is defined by the internal spacer 26, the trim breaker 22, and the wrapper flange 20. In some instances, the peripheral interior space 108 may also be partially defined by the wrapper face 66. The peripheral interior space 108 is in fluid communication with the central interior space 106, and both the central and peripheral interior spaces 106, 108 contain an insulative material 110. Accordingly, during a process in which the central interior space 106 is filled with the insulative material 110, the insulative material 110 passes around or through the internal spacer 26, and the peripheral interior space 108 is filled with the insulative material 110. Alternatively, the peripheral interior space 108 may be filled with the insulative material 110 before the central interior space 106, and the insulative material 110 may pass through one or more channels 109 (FIGS. 4A-4C) and accordingly fill the central interior space 106.

[0030] According to some aspects, the peripheral interior space 108 may be unreachable for the insulative material 110 in the central interior space 106 and may be void of the insulative material 110 or filled separately with additional insulative material 110. In other aspects, the interior space 70 may include the central interior space 106 and not the peripheral interior space 108. The internal spacer 26 may have insulative properties such that the internal spacer 26 provides insulation for the insulated panel 62 in addition to the insulative material 110. Particularly, the internal spacer 26 may be made of a material including but not limited to Expanded Polystyrene (EPS) foam. The internal spacer 26 may additionally be rigid or elastically deformable, for example.

[0031] Referring to FIGS. 3A and 4A, the wrapper flange 20 of the outer wrapper 16 maintains a spaced relationship with the recessed surface 94 and the first and second sidewalls 96, 98 of the outer cavity 24 due to the interface between the outer wrapper 16 and the trim breaker 22. At the interface between the outer wrapper 16 and the trim breaker 22, the internal spacer 26 facilitates coupling of the outer wrapper 16 and the trim breaker 22 such that contact between the trim breaker 22 and the outer wrapper 16 is indirect. As illustrated, the internal spacer 26 includes a distinct spacer 112. The distinct spacer 112 includes an elongate segment 114 extending substantially orthogonally between a first base 116 of the distinct spacer 112 and a second base 118 of the distinct spacer 112, defining an I-shaped cross-section, where the first and second bases 116, 118 of the distinct spacer 112 are wider than the elongate segment 114. The first base 116 extends along the spacer reception surface 90 of the trim breaker 22 adjacent to the outer cavity 24, and the second base 118 extends along the wrapper face 66 of the outer wrapper 16 adjacent to the wrapper flange 20. The distinct spacer 112 defines the length L2, spacing the wrapper face 66 and the spacer reception surface 90 such that the gap 28 interposes the tip 30 of the wrapper flange 20 and the recessed surface 94 of the outer cavity 24 of the trim breaker 22.

[0032] According to some aspects, the internal spacer 26 includes a plurality of separated distinct spacers 112 extending between the trim breaker 22 and the outer wrapper 16 along the outer perimeter 18. In such aspects, the first and second bases 116, 118 may have a circular or other geometric shape. In one exemplary configuration, one distinct spacer 112 may be situated at each corner 120 of the door 10 of the refrigerator 40 (FIG. 1), and distinct spacers 112 may additionally interpose the corners 120 of the door 10. In another exemplary configuration, a plurality of separated distinct spacers 112 may be situated along the outer perimeter 18 and spaced apart by a distance of one to ten millimeters. Additionally or alternatively, one distinct spacer 112 may extend between the trim breaker 22 and the outer wrapper 16, the one distinct spacer 112 extending partially or entirely along the outer perimeter 18. In configurations where the distinct spacer 112 extends along the entirety of the outer perimeter 18, the internal spacer 26 may define one or more channels 109 such that the central interior space 106 is in fluid communication with the peripheral interior space 108. Accordingly, during a process in which the central interior space 106 is filled with the insulative material 110, the insulative material 110 can pass through the one or more channels 109 and fill the peripheral interior space 108.

[0033] Referring to FIGS. 2, 3A, and 4A, the first and second bases 116, 118 of the illustrated distinct spacer 112 assist with achieving an improved connection between the outer wrapper 16 and the trim breaker 22 and a more convenient assembly of the door 10 of the refrigerator 40 (FIG. 1) as compared to known refrigerator doors. In an exemplary manufacturing process of the door 10 having a plurality of distinct spacers 112, the liner flange 68 of the inner liner 12 may be adhesively coupled to the trim breaker 22 within the inner cavity 84, and the first base 116 of each distinct spacer 112 may be adhesively coupled to the spacer reception surface 90 of the trim breaker 22. The outer wrapper 16 may then be placed over the inner liner 12 and the trim breaker 22 such that the wrapper face 66 abuts the second base 118 of each distinct spacer 112 and the wrapper flange 20 is received by the outer cavity 24, thereby creating the gap 28 between the tip 30 of the wrapper flange 20 and the recessed surface 94 of the outer cavity 24. Thereafter, the adhesive material 104 may be placed or injected into the gap 28 in the outer cavity 24 and around the wrapper flange 20. The addition of the adhesive materials 104 into the inner cavity 84 and the outer cavity 24 around the liner flange 68 and the wrapper flange 20, respectively, creates a hermetic seal that enables the vacuum sealing of the interior space 70. According to some aspects, the inner liner 12 and the trim breaker 22 may be placed over the outer wrapper 16 as opposed to the outer wrapper 16 being placed over the inner liner 12 and the trim breaker 22. According to yet another aspect, the outer wrapper 16 may be coupled to the trim breaker 22 before the inner liner 12 is coupled to the trim breaker 22 during an exemplary manufacturing process.

[0034] In some instances, the second base 118 of each distinct spacer 112 provided in the door 10 of the refrigerator 40 (FIG. 1) may be adhesively coupled to the wrapper face 66 of the outer wrapper 16, and the inner liner 12 and the trim breaker 22 may be placed over the outer wrapper 16 during assembly such that the spacer reception surface 90 of the trim breaker 22 abuts the first base 116 of each distinct spacer 112 and the wrapper flange 20 is received by the outer cavity 24. Each distinct spacer 112 may alternatively be placed onto the wrapper face 66 or the spacer reception surface 90 in an exemplary manufacturing process as opposed to being adhesively coupled to the wrapper face 66 or the spacer reception surface 90. Alternatively, both the first and second bases 116, 118 may be adhesively coupled to the spacer reception surface 90 of the trim breaker 22 and the wrapper face 66 of the outer wrapper 16, respectively, during an exemplary manufacturing process.

[0035] With reference now to FIGS. 3B and 4B, the internal spacer 26 may be a protrusion 122 projecting substantially orthogonally from the spacer reception surface 90 of the trim breaker 22 toward the wrapper face 66 of the outer wrapper 16. The protrusion 122 is in contact with the wrapper face 66 and is spaced from the wrapper flange 20 such that the wrapper flange 20, the interior side 82 of the trim breaker 22, and the protrusion 122 at least partially define the peripheral interior space 108. The protrusion 122 defines a width W that may vary between configurations. The protrusion 122 defines the length L2 and is tapered such that the width W of the protrusion 122 proximate the trim breaker 22 is greater than the width W of the protrusion 122 proximate the wrapper face 66. The taper of the protrusion 122 may vary between configurations. For example, the width W of the protrusion 122 proximate the wrapper face 66 may be substantially trivial in some configurations. Additionally or alternatively, the width W of the protrusion 122 proximate the spacer reception surface 90 may span the spacer reception surface 90. In other configurations, the protrusion 122 may be tapered such that the width W of the protrusion 122 proximate the wrapper face 66 is greater than the width W of the protrusion 122 proximate the trim breaker 22. The protrusion 122 may alternatively have no taper.

[0036] The protrusion 122 of the trim breaker 22 defines a terminal point 124 which may be squared or rounded, for example. In instances where the terminal point 124 of the protrusion 122 is adhered to the wrapper face 66 of the outer wrapper 16 during the manufacturing of the insulated panel 62, better adhesion between the protrusion 122 and the wrapper face 66 may be achieved when the terminal point 124 is wider and squared. Alternatively, less material may be used to construct the protrusion 122 having a narrower, rounded terminal point 124, which may reduce cost. It is also contemplated that the protrusion 122 may define one or more channels 109, which may be one or more apertures, extending transversely through the protrusion 122. Accordingly, the central and peripheral interior spaces 106, 108 may be in fluid communication via the one or more channels 109, and the insulative material 110 placed or injected into the central interior space 106 may pass through the one or more channels 109 and fill the peripheral interior space 108. In one nonlimiting example, the protrusion 122 defines one or more channels 109 spaced along the outer perimeter 18 such that the protrusion 122 forms a plurality of transverse ribs 125 (FIG. 4C) extending along the wrapper face 66 in a direction perpendicular to the wrapper flange 20. Here, the one or more channels 109 may be spaced apart by a distance of one to ten millimeters, for example.

[0037] With reference now to FIGS. 3C and 4D, the internal spacer 26 is a step 126 in the outer wrapper 16 along the outer perimeter 18 adjacent to the wrapper flange 20. The step 126 includes a first section 128 extending substantially orthogonally from the wrapper face 66 toward the spacer reception surface 90 of the trim breaker 22. The first section 128 further extends between a first end 130 and a second end 132, wherein the first end 130 is connected to the wrapper face 66 and the second end 132 is proximate the spacer reception surface 90 of the trim breaker 22. In some instances, the second end 132 of the first section 128 may abut the spacer reception surface 90. The step 126 further includes a second section 134 extending substantially orthogonally from the first section 128. The second section 134 further extends between a third end 136 and a fourth end 138, where the third end 136 is connected to the second end 132 of the first section 128 and the fourth end 138 is connected to the wrapper flange 20. The second section 134 is in contact with the spacer reception surface 90, and the wrapper flange 20 extends substantially orthogonally from the fourth end 138 of the second section 134. Furthermore, the first section 128 defines a first section length SL1, which may be the length L2 of the internal spacer 26.

[0038] The wrapper flange 20 of the outer wrapper 16 is spaced from the first section 128 of the step 126 by a distance equal to a second section length SL2 of the second section 134, and the wrapper flange 20 extends from the second section 134 such that the wrapper flange 20 is centered between the first and second sidewalls 96, 98 of the outer cavity 24 and the gap 28 interposes the tip 30 of the wrapper flange 20 and the recessed surface 94 of the outer cavity 24. The intersections of the wrapper face 66 and the first section 128, the first section 128 and the second section 134, and the second section 134 and the wrapper flange 20 are beveled, but such intersections may be pointed in other instances. As illustrated in FIG. 3C, the step 126, the trim breaker 22, and the outer wrapper 16 define the central interior space 106. In some instances, additional insulative material 110 may be disposed within a pocket 140 defined at least partially by the outer wrapper 16, the trim breaker 22, and the exterior door wall to improve insulative properties of the door 10 of the refrigerator 40 (FIG. 1). The pocket 140 may be filled with additional insulative material 110 separate from the insulative material 110 in the central interior space 106. Alternatively, the pocket 140 may be filled with the insulative material 110 through one or more channels 109 (FIGS. 4A-4C) defined by the step 126 of the outer wrapper 16 and / or the wrapper face 66 of the outer wrapper 16 such that the pocket 140 and the central interior space 106 are in fluid communication. Accordingly, when the central interior space 106 is filled with the insulative material 110, the pocket 140 may also be filled with the insulative material 110. Moreover, the pocket 140 may also be vacuum sealed and define a vacuum therein.

[0039] Referring to FIGS. 1 and 2, it is contemplated that the insulated panel 62 may additionally or alternatively be integrated into the cabinet 42 of the refrigerator 40. For example, the insulated panel 62 may extend between the external cabinet surface 46 of the cabinet 42 and the internal cabinet surface 47 of the internal compartment 48 of the cabinet 42. The insulated panel 62 may further define the external cabinet surface 46 of the cabinet 42 and the internal cabinet surface 47 of the internal compartment 48. In another example, the refrigerator 40 may include a plurality of insulated panels 62, wherein each of the plurality of insulated panels 62 is disposed within one of the plurality of cabinet panels 44.

[0040] With reference to FIGS. 1-3C, in instances where the gap 28 is not provided between the outer wrapper 16 and the recessed surface 94 of the outer cavity 24 of the trim breaker 22, variation in the length L1 of the wrapper flange 20 may result due to the manufacturing of the outer wrapper 16, which in turn can cause a variation in thickness T2 of the insulated panel 62 and thickness T1 of the door 10 of the refrigerator 40. The interface between the trim breaker 22 and the outer wrapper 16 disclosed herein advantageously includes the internal spacer 26 extending between the trim breaker 22 and the outer wrapper 16 within the outer perimeter 18, thereby separating the trim breaker 22 and the outer wrapper 16 such that the gap 28 interposes the tip 30 of the wrapper flange 20 and the recessed surface 94 of the outer cavity 24. The gap 28 allows for a variance in the length L1 of the wrapper flange 20, providing the insulated panel 62 and the door 10 of the refrigerator 40 with a decreased thickness variability. The gap 28 also allows for the convenient placement or injection of the adhesive material 104 in the outer cavity 24 between the wrapper flange 20 and each of the first and second sidewalls 96, 98 and between the tip 30 of the wrapper flange 20 and the recessed surface 94, which may result in improved adhesion between the wrapper flange 20 and the trim breaker 22 and therefore improved durability of the insulated panel 62 and the door 10 of the refrigerator 40.

[0041] It will be understood by one having ordinary skill in the art that construction of the described disclosure and other components is not limited to any specific material. Other exemplary embodiments of the disclosure disclosed herein may be formed from a wide variety of materials, unless described otherwise herein.

[0042] According to one aspect of the present disclosure, a refrigerator includes a vacuum insulated door having an inner liner and an outer wrapper extending along the inner liner, wherein the inner liner defines a first perimeter, and wherein the outer wrapper defines a second perimeter, and a trim breaker coupled to the inner liner and the outer wrapper such that the inner liner is not in direct contact with the outer wrapper, the trim breaker defining an inner cavity configured to receive a liner flange extending from the first perimeter and an outer cavity configured to receive a wrapper flange extending from the second perimeter. The refrigerator further defines an internal spacer disposed between the outer wrapper and the trim breaker such that the wrapper flange is in a spaced relationship with the outer cavity, wherein the internal spacer is in contact with a spacer reception surface of the trim breaker, and wherein the internal spacer is a step in the outer wrapper, the step including a first section extending between the outer wrapper and the trim breaker and a second section extending along the spacer reception surface of the trim breaker between the first section and the wrapper flange, wherein the second section is in contact with the trim breaker, and wherein the second section defines the second perimeter.

[0043] According to another aspect, the liner and wrapper flanges extend along the first and second perimeters, respectively.

[0044] According to yet another aspect, the liner and wrapper flanges extend from the inner liner and the outer wrapper, respectively, in the same direction.

[0045] According to still yet another aspect, the internal spacer extends along the second perimeter.

[0046] According to yet another aspect, the first section extends between the trim breaker and the outer wrapper in a direction substantially parallel to the liner and wrapper flanges.

[0047] According to another aspect, the internal spacer defines the second perimeter.

[0048] According to yet another aspect, a tip of the wrapper flange is spaced from the outer cavity in a direction substantially parallel to the wrapper flange.

[0049] According to still yet another aspect, the wrapper flange is offset from the liner flange in at least two directions.

[0050] According to yet another aspect, an adhesive material is received by the inner and outer cavities such that the inner liner, the outer wrapper, and the trim breaker define a sealed interior space, and wherein the sealed interior space has a pressure that is substantially less than the pressure exterior to the vacuum insulated door.

[0051] According to another aspect of the present disclosure, an insulated panel for a refrigerator includes an inner liner defining a liner flange extending along a first perimeter, an outer wrapper defining a wrapper flange extending along a second perimeter, wherein the first perimeter is smaller than the second perimeter, and wherein the inner liner and the outer wrapper extend along substantially skew planes, and a trim breaker coupled to both the inner liner and the outer wrapper, the trim breaker defining an inner cavity and an outer cavity, wherein the liner flange is disposed in the inner cavity, and wherein the wrapper flange is disposed in the outer cavity. The insulated panel further includes a sealed interior space defined by the inner liner, the outer wrapper, and the trim breaker, wherein the sealed interior space is configured to contain insulative material, and wherein gas molecules have been largely evacuated within the sealed interior space, resulting in a vacuum within the sealed interior space relative to ambient pressure outside of the sealed interior space, and an internal spacer extending between the trim breaker and the outer wrapper such that a gap interposes the wrapper flange and the outer cavity, wherein the wrapper flange is spaced from the internal spacer, wherein the internal spacer is in contact with both the trim breaker and the outer wrapper, and wherein the internal spacer is outside of the outer cavity.

[0052] According to another aspect, the internal spacer protrudes from the trim breaker proximate the outer cavity.

[0053] According to yet another aspect, the internal spacer is tapered toward the outer wrapper.

[0054] According to still yet another aspect, the internal spacer defines one or more channels extending transversely through the internal spacer.

[0055] According to yet another aspect, the sealed interior space includes a central interior space and a peripheral interior space, wherein the central interior space is defined by the internal spacer, the trim breaker, the inner liner, and the outer wrapper, wherein the peripheral interior space is defined by the internal spacer, the wrapper flange, and the trim breaker, and wherein the peripheral interior space is in fluid communication with the central interior space through the one or more channels.

[0056] According to another aspect, the outer cavity defines a pair of sidewalls and a recessed surface extending between the pair of sidewalls, wherein the wrapper flange is spaced from the recessed surface and each of the pair of sidewalls, and wherein an adhesive material is disposed between the wrapper flange and the recessed surface and between the wrapper flange and each of the pair of sidewalls.

[0057] According to another aspect of the present disclosure, a refrigerator door includes an inner liner defining a first perimeter, an outer wrapper defining a second perimeter that is larger than the first perimeter, the outer wrapper extending along the inner liner, wherein a wrapper flange extends from the outer wrapper along the second perimeter, and a trim breaker coupled to the inner liner proximate the first perimeter and the wrapper flange of the outer wrapper, the trim breaker defining an outer cavity receiving the wrapper flange. The refrigerator door further includes an internal spacer disposed between the first and second perimeters and extending between the trim breaker and the outer wrapper, wherein the internal spacer is spaced from the wrapper flange, and wherein the trim breaker and the outer wrapper are spaced by the internal spacer such that a gap interposes the outer cavity and a tip of the wrapper flange, the gap being defined in a direction substantially parallel to the wrapper flange.

[0058] According to another aspect, the internal spacer is tapered toward the outer wrapper and protrudes from the trim breaker.

[0059] According to yet another aspect, the internal spacer defines one or more channels.

[0060] According to still yet another aspect, the internal spacer surrounds a central interior space, wherein the central interior space is vacuum sealed and contains insulative material.

[0061] According to yet another aspect, a peripheral interior space is defined between the internal spacer and the wrapper flange, wherein the peripheral interior space is vacuum sealed and contains insulative material.

[0062] For purposes of this disclosure, the term “coupled” (in all of its forms, couple, coupling, coupled, etc.) generally means the joining of two components (electrical or mechanical) directly or indirectly to one another. Such joining may be stationary in nature or movable in nature. Such joining may be achieved with the two components (electrical or mechanical) and any additional intermediate members being integrally formed as a single unitary body with one another or with the two components. Such joining may be permanent in nature or may be removable or releasable in nature unless otherwise stated.

[0063] It is also important to note that the construction and arrangement of the elements of the disclosure as shown in the exemplary embodiments is illustrative only. Although only a few embodiments of the present innovations have been described in detail in this disclosure, those skilled in the art who review this disclosure will readily appreciate that many modifications are possible (e.g., variations in sizes, dimensions, structures, shapes and proportions of the various elements, values of parameters, mounting arrangements, use of materials, colors, orientations, etc.) without materially departing from the novel teachings and advantages of the subject matter recited. For example, elements shown as integrally formed may be constructed of multiple parts or elements shown as multiple parts may be integrally formed, the operation of the interfaces may be reversed or otherwise varied, the length or width of the structures and / or members or connector or other elements of the system may be varied, the nature or number of adjustment positions provided between the elements may be varied. It should be noted that the elements and / or assemblies of the system may be constructed from any of a wide variety of materials that provide sufficient strength or durability, in any of a wide variety of colors, textures, and combinations. Accordingly, all such modifications are intended to be included within the scope of the present innovations. Other substitutions, modifications, changes, and omissions may be made in the design, operating conditions, and arrangement of the desired and other exemplary embodiments without departing from the spirit of the present innovations.

[0064] It will be understood that any described processes or steps within described processes may 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 are not to be construed as limiting.

Examples

Embodiment Construction

[0019]The present illustrated embodiments reside primarily in combinations of method steps and apparatus components related to an interface between a wrapper and a trim breaker of an insulated panel for a refrigerator door. Accordingly, the apparatus components and method steps have been represented, where appropriate, by conventional symbols in the drawings, showing only those specific details that are pertinent to understanding the embodiments of the present disclosure so as not to obscure the disclosure with details that will be readily apparent to those of ordinary skill in the art having the benefit of the description herein. Further, like numerals in the description and drawings represent like elements.

[0020]The terms “including,”“comprises,”“comprising,” or any other variation thereof, are intended to cover a non-exclusive inclusion, such that a process, method, article, or apparatus that comprises a list of elements does not include only those elements but may include other ...

Claims

1. A refrigerator, comprising:a vacuum insulated door having an inner liner and an outer wrapper extending along the inner liner, wherein the inner liner defines a first perimeter, and wherein the outer wrapper defines a second perimeter;a trim breaker coupled to the inner liner and the outer wrapper such that the inner liner is free of direct contact with the outer wrapper, the trim breaker defining:an inner cavity configured to receive a liner flange extending from the first perimeter; andan outer cavity configured to receive a wrapper flange extending from the second perimeter; andan internal spacer disposed between the outer wrapper and the trim breaker such that the wrapper flange is in a spaced relationship with the outer cavity, wherein the internal spacer is in contact with a spacer reception surface of the trim breaker, and wherein the internal spacer is a step in the outer wrapper, the step including:a first section extending between the outer wrapper and the trim breaker; anda second section extending along the spacer reception surface of the trim breaker between the first section and the wrapper flange, wherein the second section is in contact with the trim breaker, and wherein the second section defines the second perimeter.

2. The refrigerator of claim 1, wherein the liner flange and the wrapper flange extend along the first and second perimeters, respectively.

3. The refrigerator of claim 1, wherein the liner flange and the wrapper flange extend from the inner liner and the outer wrapper, respectively, in the same direction.

4. The refrigerator of claim 1, wherein the internal spacer extends along the second perimeter.

5. The refrigerator of claim 1, wherein the first section extends between the trim breaker and the outer wrapper in a direction substantially parallel to the liner and wrapper flanges.

6. The refrigerator of claim 1, wherein the internal spacer defines the second perimeter.

7. The refrigerator of claim 1, wherein a tip of the wrapper flange is spaced from the outer cavity in a direction substantially parallel to the wrapper flange.

8. The refrigerator of claim 1, wherein the wrapper flange is offset from the liner flange in at least two directions.

9. The refrigerator of claim 1, wherein an adhesive material is received by the inner and outer cavities such that the inner liner, the outer wrapper, and the trim breaker define a sealed interior space, and wherein the sealed interior space has a pressure that is substantially less than the pressure exterior to the vacuum insulated door.

10. An insulated panel for a refrigerator, comprising:an inner liner defining a liner flange extending along a first perimeter;an outer wrapper defining a wrapper flange extending along a second perimeter, wherein the first perimeter is smaller than the second perimeter, and wherein the inner liner and the outer wrapper extend along substantially skew planes;a trim breaker coupled to both the inner liner and the outer wrapper, the trim breaker defining an inner cavity and an outer cavity, wherein the liner flange is disposed in the inner cavity, and wherein the wrapper flange is disposed in the outer cavity;a sealed interior space defined by the inner liner, the outer wrapper, and the trim breaker, wherein the sealed interior space is configured to contain insulative material, and wherein gas molecules have been largely evacuated within the sealed interior space, resulting in a vacuum within the sealed interior space relative to ambient pressure outside of the sealed interior space; andan internal spacer extending between the trim breaker and the outer wrapper such that a gap interposes the wrapper flange and the outer cavity, wherein the wrapper flange is spaced from the internal spacer, wherein the internal spacer is in contact with both the trim breaker and the outer wrapper, and wherein the internal spacer is outside of the outer cavity.

11. The insulated panel for a refrigerator of claim 10, wherein the internal spacer protrudes from the trim breaker proximate the outer cavity.

12. The insulated panel for a refrigerator of claim 11, wherein the internal spacer is tapered toward the outer wrapper.

13. The insulated panel for a refrigerator of claim 12, wherein the internal spacer defines one or more channels extending transversely through the internal spacer.

14. The insulated panel for a refrigerator of claim 13, wherein the sealed interior space includes a central interior space and a peripheral interior space, wherein the central interior space is defined by the internal spacer, the trim breaker, the inner liner, and the outer wrapper, wherein the peripheral interior space is defined by the internal spacer, the wrapper flange, and the trim breaker, and wherein the peripheral interior space is in fluid communication with the central interior space through the one or more channels.

15. The insulated panel for a refrigerator of claim 10, wherein the outer cavity defines a pair of sidewalls and a recessed surface extending between the pair of sidewalls, wherein the wrapper flange is spaced from the recessed surface and each of the pair of sidewalls, and wherein an adhesive material is disposed between the wrapper flange and the recessed surface and between the wrapper flange and each of the pair of sidewalls.

16. A refrigerator door, comprising:an inner liner defining a first perimeter;an outer wrapper defining a second perimeter that is larger than the first perimeter, the outer wrapper extending along the inner liner, wherein a wrapper flange extends from the outer wrapper along the second perimeter;a trim breaker coupled to the inner liner proximate the first perimeter and the wrapper flange of the outer wrapper, the trim breaker defining an outer cavity receiving the wrapper flange; andan internal spacer disposed between the first and second perimeters and extending between the trim breaker and the outer wrapper, wherein the internal spacer is spaced from the wrapper flange, and wherein the trim breaker and the outer wrapper are spaced by the internal spacer such that a gap interposes the outer cavity and a tip of the wrapper flange, the gap being defined in a direction substantially parallel to the wrapper flange.

17. The refrigerator door of claim 16, wherein the internal spacer is tapered toward the outer wrapper and protrudes from the trim breaker.

18. The refrigerator door of claim 16, wherein the internal spacer defines one or more channels.

19. The refrigerator door of claim 16, wherein the internal spacer surrounds a central interior space, and wherein the central interior space is vacuum sealed and contains insulative material.

20. The refrigerator door of claim 16, wherein a peripheral interior space is defined between the internal spacer and the wrapper flange, and wherein the peripheral interior space is vacuum sealed and contains insulative material.

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