U.S. patent application number 14/634936 was filed with the patent office on 2016-09-08 for gas barrier for vacuum insulation.
This patent application is currently assigned to WHIRLPOOL CORPORATION. The applicant listed for this patent is WHIRLPOOL CORPORATION. Invention is credited to PAUL B. ALLARD, CAMILLE KITE.
Application Number | 20160258671 14/634936 |
Document ID | / |
Family ID | 56848215 |
Filed Date | 2016-09-08 |
United States Patent
Application |
20160258671 |
Kind Code |
A1 |
ALLARD; PAUL B. ; et
al. |
September 8, 2016 |
GAS BARRIER FOR VACUUM INSULATION
Abstract
A gas barrier for a vacuum insulated structure of a refrigerator
is provided. The gas barrier includes a plastic trim breaker; a
metal outer panel a metal inner panel and insulation between the
outer and inner metal panels. The gas barrier for a vacuum
insulated structure further includes a PVD metal coating applied to
the an inside surface of the plastic trim breaker to provide a
barrier layer to the plastic trim breaker, wherein the PVD coating
on the inside of the plastic trim breaker contacts the inner and
outer metal outer panels to prevent heat or gas from entering the
insulated structure and decreasing the effectiveness of the
insulation over time.
Inventors: |
ALLARD; PAUL B.; (COLOMA,
MI) ; KITE; CAMILLE; (FRANKLIN, WI) |
|
Applicant: |
Name |
City |
State |
Country |
Type |
WHIRLPOOL CORPORATION |
Benton Harbor |
MI |
US |
|
|
Assignee: |
WHIRLPOOL CORPORATION
Benton Harbor
MI
|
Family ID: |
56848215 |
Appl. No.: |
14/634936 |
Filed: |
March 2, 2015 |
Current U.S.
Class: |
1/1 |
Current CPC
Class: |
F25D 23/066 20130101;
F25D 23/085 20130101; F25D 2201/14 20130101; F25D 23/065
20130101 |
International
Class: |
F25D 23/06 20060101
F25D023/06 |
Claims
1. A vacuum insulated structural component of a refrigerator with a
gas barrier comprising: a plastic trim breaker; a metal outer
panel; a metal inner panel; insulation between the outer and inner
metal panels; and a physical vapor deposited metal coating applied
to an inside surface of the plastic trim breaker to provide a
barrier layer to the plastic trim breaker, wherein the physical
vapor deposited coating on the inside of the plastic trim breaker
has a thickness of at least about 0.015 mm and abuts or is adjacent
to surfaces of the inner and outer metal panels to prevent heat or
gas from entering the insulated structure between the inner and
outer metal panels.
2. The vacuum insulated structural component of a refrigerator of
claim 1, further comprising a cabinet seal surrounded by the
insulation, the outer and inner metal panels and the barrier layer
on the inside of the plastic trim breaker.
3. The vacuum insulated structural component of a refrigerator of
claim 1, further comprising a flange extending inwardly from at
least one of the outer and inner metal panels toward the other of
the outer and inner metal panels.
4. The vacuum insulated structural component of a refrigerator of
claim 3, further comprising a flange extending from each of the
outer and inner metal panels.
5. The vacuum insulated structural component of a refrigerator of
claim 4, wherein the flanges generally extend in a direction toward
each other.
6. The vacuum insulated structural component of a refrigerator of
claim 5, wherein the barrier layer substantially prevents heat from
entering the structure between the flanges.
7. The vacuum insulated structural component of a refrigerator of
claim 3, wherein the barrier layer prevents the space between the
inner and outer metal panels from conducting heat or gas.
8. The vacuum insulated structural component of a refrigerator of
claim 1, wherein the insulation is formed from the group consisting
of fumed silica, fiberglass, precipitated silica, glass
microspheres or open cell polyurethane foam.
9. The vacuum insulated structural component of a refrigerator of
claim 1, wherein the barrier layer is formed of aluminum or other
barrier material and the vacuum insulated structural component is a
wall of the refrigerator or a door of a compartment of the
refrigerator and wherein an interior of the door comprises recessed
dyke walls.
10. A three-dimensional vacuum insulated refrigerator liner, the
three-dimensional refrigerator liner comprising: an interior
three-dimensional liner having an internal side facing toward the
interior of the refrigerator structure and a visible side which is
visible to a consumer viewing the inside of the refrigerator; and a
metal coating applied by physical vapor deposition to the internal
side or the visual side of the interior three-dimensional liner to
form a barrier layer on the interior panel; wherein the barrier
layer prevents gas from permeating easily through the
three-dimensional liner.
11. The vacuum insulated three-dimensional refrigerator liner of
claim 10, wherein the three-dimensional interior liner is
constructed of HIPS or another high impact liner material.
12. The vacuum insulated three-dimensional refrigerator liner of
claim 10, wherein the liner is part of a refrigerator door.
13. The vacuum insulated three-dimensional refrigerator liner of
claim 10, wherein the three-dimensional liner is part of a
refrigerator cabinet.
14. The vacuum insulated three-dimensional refrigerator liner of
claim 10, wherein the three-dimensional refrigerator liner is part
of an under counter refrigerator.
15. The vacuum insulated three-dimensional refrigerator liner of
claim 10, wherein the barrier layer is formed of aluminum or other
barrier material.
16. The vacuum insulated three-dimensional refrigerator liner of
claim 10, wherein the interior liner comprises bosses to provide
attachment to the three-dimensional interior liner.
17. The vacuum insulated three-dimensional refrigerator liner of
claim 10, wherein the three-dimensional interior liner has ribs to
provide enhanced strength to the three-dimensional interior
liner.
18. A refrigerator, the refrigerator comprising: a plastic trim
breaker; a three-dimensional liner; a wrapper which surrounds the
liner; a back plate secured to the back of the three-dimensional
liner; insulation between the three-dimensional liner and the
wrapper, and a physical vapor deposition metal coating applied to
the inside surface of the plastic trim breaker to provide a barrier
layer to the plastic trim breaker, wherein a portion of the barrier
layer contacts a portion of both the three-dimensional liner and
wrapper to prevent heat or gas from entering the interior of the
refrigerator restructure.
19. The refrigerator of claim 18, wherein the barrier layer is
formed of aluminum.
20. The refrigerator of claim 18, wherein the trim breaker includes
recesses to receive the inner three-dimensional liner and the
wrapper.
Description
FIELD OF THE DISCLOSURE
[0001] This application relates to a panel or cabinet for
refrigeration. In particular, the present disclosure relates to a
barrier layer of aluminum or another suitable barrier layer for an
interior surface of three-dimensional, shaped (3D) vacuum structure
or to provide a barrier layer for a thermal breaker between a metal
outer cabinet and a metal inner liner or panel.
BACKGROUND
[0002] Various types of insulated cabinet and insulated door
structures have been developed for refrigerators, freezers, and
other such appliances. Insulated appliance door and cabinet
structures may include polyurethane foam, polystyrene or other
insulating material that is positioned between an outer door skin
or wrapper and an inner door liner. However, known insulated
appliance structures may suffer from various drawbacks.
[0003] Vacuum panels provide superior insulation properties over
traditional polyurethane (PU) foam. In order to maintain the vacuum
inside the panel, the enclosure of the panel must contain a barrier
material to prevent gas from entering the panel and losing vacuum
inside the panel over time. When considering a vacuum insulated
structure, the walls of the structure must have a barrier layer to
prevent gas(es) from entering the structure. Plastics do not
typically have good barrier properties, while metals typically do
have good barrier properties. Vacuum panels traditionally use
aluminum foil or a metalized film to provide barrier properties.
However, a foil or film is difficult to match to a 3D shape.
Another method is to use ethylene vinyl alcohol (EVOH) or other
polymeric material barriers that can be co-extruded or laminated
with (High Impact Polystyrene (HIPS). This sheet can then be
thermoformed into a part such as a door or cabinet liner. The
drawback is that this is limited to thermoforming. If a more
complex part, such as one that is made by injection molding, is
desired, these solutions do not work.
SUMMARY
[0004] An aspect of the present disclosure is to use Physical Vapor
Deposition (PVD) to create a thin layer of aluminum or other
barrier material on a part, often a shaped and structured
three-dimensional part. One application is to apply it on the
internal side of the plastic door liner (FIGS. 1 & 2). The
interior of the plastic door liner would be coated with aluminum to
provide good barrier properties and could be assembled with a metal
outer panel and filled with a filler material (fiberglass or fumed
silica) appropriate for building a vacuum insulated door. One
advantage of using PVD to cover the inside surface of the liner
with a barrier layer is that the inside of the liner does not need
to be flat. It could have a shape to match the outside of the liner
or could have additional features such as ribs for strength or
bosses for attachment. If both sides of the door are plastic, the
internal sides of both panels would be treated with PVD.
[0005] Another application is to apply a thermal breaker between a
metal outer cabinet and a metal inner liner. A cabinet with metal
walls will provide good barrier properties, but it will also
conduct heat around the flange. A solution to the heat bridge is to
use a plastic breaker strip to provide a barrier to the heat
conduction. However, this plastic breaker strip does not have good
vapor (gas) barrier properties and will allow gas to accumulate in
the vacuum structure and reduce insulation performance over time. A
barrier layer of metal can be applied to the interior surface of
the breaker strip to give the breaker strip good barrier
performance. By being on the inside surface, the PVD barrier layer
typically will not be visible to consumers. The thickness of the
barrier layer is quite thin, from approximately 0.001 mm to about
0.015 mm and it will not transfer heat into the cabinet as much as
a thicker material such as the wall.
[0006] An aspect of the present disclosure is generally directed
toward a gas barrier for a vacuum insulated structure or liner of a
refrigerator, the gas barrier for the gas insulated structure of a
refrigerator includes a plastic trim breaker; a metal outer panel;
a metal inner panel; insulation between the outer and inner metal
panels; and a PVD metal coating applied to the an inside surface of
the plastic trim breaker to provide a barrier layer to the plastic
trim breaker. The PVD coating on the inside of the plastic trim
breaker abuts the outside surfaces of the inner and outer metal
outer panels to prevent gasses from entering the insulated
structure and decreasing the effectiveness of the insulation over
time.
[0007] Another application is to provide a 3D vacuum insulated
refrigerator structure. The 3D refrigerator liner includes an
interior 3D liner having an internal side facing to the interior of
the refrigerator structural component, such as a door or wall, and
a visible side which is visible to a consumer viewing the inside of
the refrigerator; and a metal coating applied by PVD to the
internal side of the interior 3D liner to form a barrier layer on
the interior panel; wherein the barrier layer prevents gas from
permeating easily through the 3D liner.
[0008] Another application is to provide a refrigerator including a
plastic trim breaker; a 3D liner; a wrapper which surrounds the
liner; a back plate secured to the back of the 3D liner. Insulation
is provided between the 3D liner and the wrapper, and a PVD metal
coating applied to the an inside surface of the plastic trim
breaker to provide a barrier layer to the plastic trim breaker,
wherein a portion of the barrier layer abuts at least a portion of
both the 3D liner and wrapper and contacts at least a portion of
the plastic trim breaker that contacts the 3D liner and wrapper, to
prevent heat from entering the structure.
[0009] 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
[0010] The foregoing summary, as well as the following detailed
description of the disclosure, will be better understood when read
in conjunction with the appended drawings. For the purpose of
illustration, there are shown in the drawings, certain
embodiment(s) which are presently preferred. It should be
understood, however, that the disclosure is not limited to the
precise arrangements and instrumentalities shown. Drawings are not
necessary to scale. Certain features may be exaggerated in scale or
shown in schematic form in the interest of clarity and
conciseness.
[0011] FIG. 1A is a perspective view of a visible side of an
interior door panel or liner, according to an exemplary
embodiment;
[0012] FIG. 1B is a perspective view of the interior side of an
interior door panel or liner of FIG. 1A;
[0013] FIG. 2A is a perspective view of a standard panel or liner
material;
[0014] FIG. 2B is a perspective view of an interior view of an
interior door panel or liner having an aluminum layer or similar
barrier layer which is applied through PVD, according to an
exemplary embodiment of the present disclosure;
[0015] FIG. 3 is a cross-sectional view of an exemplary embodiment
having a plastic trim breaker with a metal interior coating
creating a barrier layer, which provides a thermal break between
two metal panels;
[0016] FIG. 4 is an exploded view of FIG. 3;
[0017] FIG. 5 is frontal view of the structure of FIG. 4;
[0018] FIG. 6A is a cross-sectional view of FIG. 5 taken along
lines 6-6;
[0019] FIGS. 6B and 6C are alternate exemplary embodiments of the
plastic trim breaker of FIG. 3 and the inner and outer metal panels
of FIG. 3;
[0020] FIG. 7A is a perspective view of a HIPS panel or liner
having reinforcing ribs;
[0021] FIG. 7B is a partial perspective view of a HIPS panel or
liner having reinforcing ribs and a boss;
[0022] FIG. 8 is a perspective view of a HIPS panel or liner having
no ribs or bosses;
[0023] FIG. 9 is a perspective view of a freezer door; and
[0024] FIG. 10 is a cross-sectional view of FIG. 9 taken along
lines 10-10 of FIG. 9.
DETAILED DESCRIPTION OF THE PRESENT DISCLOSURE
[0025] It is to be understood that the present disclosure is not
limited to the particular description below, as many variations of
the present disclosure may be made and still fall within the scope
of the appended claims. It is also to be understood that the
terminology employed is for the purpose of describing present
disclosure, and is not intended to be limiting in any manner.
[0026] In this specification and the appended claims, the singular
forms "a," "an" and "the" include plural reference unless the
context clearly dictates otherwise. The present disclosure is
generally directed toward a 3D vacuum insulated appliance
structural component.
[0027] For purposes of description herein, The terms "upper,"
"lower," "right," "left," "rear," "front," "vertical,"
"horizontal," "top," "bottom," "left," "right" and derivatives
thereof shall relate to the disclosure as oriented in FIGS. 1A-1B.
However, it is to be understood that the disclosure may assume
various alternative orientations, except where expressly specified
to the contrary. It is also to be understood that the specific
devices and processes illustrated in the attached drawings, and
described in the following specification are simply present
disclosure of the inventive concepts defined in the appended
claims. Hence, specific dimensions and other physical
characteristics relating to the present disclosure disclosed herein
are not to be considered as limiting, unless the claims expressly
state otherwise.
[0028] FIG. 1A is a perspective view of a 3D interior door or
cabinet liner 10. The door or cabinet liner is generally formed of
high-impact polystyrene (HIPS), but is not limited to such
material. FIG. 1A shows the visible side of the interior door or
cabinet liner. The visible side is visible to a user of the
refrigerator, who has opened the door of the refrigerator and is
looking into the refrigerator door or cabinet. The interior door or
cabinet liner may be used as an interior liner of a refrigerator
door or refrigerator cabinet. In addition, the interior liner may
be used for an under counter refrigerator, as well as a
refrigerator of any other shape, as would be understood by those of
ordinary skill in the art.
[0029] FIG. 1B is a rear perspective view of the 3D HIPS door or
cabinet liner of FIG. 1A. FIG. 1B shows the side of the door or
cabinet liner 20 that is the side facing the interior of the
refrigerator cabinet structure between the line and the exterior of
the appliance cabinet, and is not visible to a user. In FIG. 1B, a
coating of aluminum or other barrier material is applied to the
interior surface through a physical vapor deposition (PVD) process.
The applied coating forms a barrier layer that prevents gases from
entering the structure over time, and reduces the effectiveness of
the insulation of the refrigerator.
[0030] FIG. 2A is a perspective view of a cutaway portion of an
interior door or cabinet liner 30. The interior door or cabinet
liner 30 is formed of HIPS and is a standard liner made from HIPS.
The door or cabinet liner 30 of FIG. 2A does not have the coating
applied by a PVD process using aluminum or another barrier layer.
Thus, the drawback of FIG. 2 is that gases can easily permeate
through the HIPS material through the liner, as shown by the arrows
in the Figure.
[0031] FIG. 2B, is a perspective view of a cutaway portion of the
HIPS door or cabinet liner of FIG. 2A. The exception is that this
Figure shows the door or cabinet liner 40 having the layer of
aluminum or similar barrier material that is applied by PVD to
produce a barrier layer. As shown by arrows in the figure, gases
reaching the door or cabinet liner from the side that is visible to
the user do not easily permeate through the aluminum or other
barrier material layer coated on the HIPS liner through the PVD
process, and reflects backwardly towards the visible portion of the
cabinet or door of the refrigerator. This exemplary embodiment can
also be applied to a freezer associated with a refrigerator or to a
stand-alone freezer.
[0032] FIG. 3 is directed to another exemplary embodiment. FIG. 3
is directed to an embodiment having a plastic trim breaker. The
plastic trim breaker provides a thermal break between two metal
plates. The embodiment is generally represented by lead line 50.
Plastic trim breaker 51 provides a thermal break between metal
outer panel 52 and metal inner panel 54. Between the metal outer
panel 52 and the metal inner panel 54 is an insulation layer 55,
which is generally formed of fumed silica or fiberglass, but is not
limited thereto. Above the insulation and also abutting the metal
outer panel 52 and the metal inner panel 54 is a seal 53. The seal
is made of a gasket material, as would be understood by one of
ordinary skill in the art. Because the seal is well known to
artisans, it is not further described herein. The upper portions of
the outer metal panel 52 and the inner metal panel 52 have inwardly
extending flanges, unlabeled, which extend inwardly toward each
other but leave a gap between the flanges. Although the flanges are
shown in FIG. 3 as being thin and extending inwardly towards each
other with a large gap there between, this is exemplary only and
the exemplary embodiments are not limited thereto. In addition,
coated on the inside of the plastic trim breaker 51 is a coating of
aluminum or other suitable barrier layer material 56. The aluminum
or other suitable barrier layer material is coated onto the inside
of the plastic trim breaker 51 by a PVD process. The coated layer
serves as a barrier material. The barrier layer 56 serves to
prevent heat or gas from entering the area between the flanges and
typically extends between and across the space between the flanges.
A cabinet or door with metal walls will conduct heat in the area
between the flanges if no barrier layer 56 is provided. To prevent
heat or gas from entering through the plastic trim 1 in the area
between the flanges, the barrier layer is provided.
[0033] FIG. 4 is an exploded view of FIG. 3. In FIG. 4, the
insulation and gasket are not shown. FIG. 4 shows plastic trim 51,
inner metal panel 54, and outer wrapper 52. The outer wrapper is an
outer metal panel that surrounds inner metal panel 54. Attached to
the back of wrapper 52 is a back plate 58.
[0034] FIG. 5 is a front view of FIG. 4 and illustrates plastic
trim breaker 51.
[0035] FIG. 6A is a cross-sectional view of FIG. 6 taken along
lines 6-6 of FIG. 5. FIG. 6A shows the relationship between inner
metal panel 54 and outer metal panel 52.
[0036] FIG. 6B is an exemplary embodiment of an exploded view of a
portion of FIG. 6A, as shown in FIG. 6A, by dot and dash lines.
FIG. 6B shows plastic trim breaker 51 having recesses 59 therein
for receiving edges of outer metal panel 52 and inner metal panel
54. Metal panels 52 and 54 are secured to recesses 59 in the
plastic trim breaker 51 by glue or other suitable connection,
typically an adhesive connection.
[0037] Barrier layer 56, which may be aluminum, is formed by a PVD
process. The barrier layer 56 typically has a thickness of from
about 0001 mm to about 0.015 mm.
[0038] FIG. 6C is another exemplary embodiment, which represents a
different structure for the plastic trim breaker 51. In this
exemplary embodiment, as shown in FIG. 6C, the plastic trim breaker
51' has a recess facing inwardly toward a front surface of the
plastic trim breaker. In contrast, in FIG. 6B, the recess faces in
an opposite direction.
[0039] FIG. 7A is a perspective view of a HIPS liner, similar to
FIG. 2B, but having ribs for strengthening the structure. FIG. 7A
is an interior view of an interior door panel or liner.
[0040] FIG. 7B is an exploded view of a portion of FIG. 7A, taken
from the dot-dash line labeled FIG. 7B in FIG. 7A. FIG. 7B shows
ribs 70-73. In addition, FIG. 7b shows boss 74 for connection of
the HIPS liner or panel to another part of the refrigerator
structure.
[0041] FIG. 8 is a perspective view of an interior HIPS panel or
liner. FIG. 8 is a view facing internally into the interior
structure of the refrigerator or freezer.
[0042] FIG. 9 is a perspective view of an entire door of a freezer
compartment of a French door bottom mount configuration
refrigeration or freezer. This exemplary embodiment is not limited
to a freezer door and can be configured for a refrigerator door,
cabinet wall, or for a pantry door of an appliance. FIG. 9 shows
door 80.
[0043] FIG. 10 is a cross sectional view of FIG. 9 taken along line
10-10 of FIG. 9. FIG. 10 illustrates door 80. In this exemplary
embodiment, the entire freezer door is made from 3D HIPS liners. In
FIG. 10, reference numeral 82 represents the connection between two
liners. In addition, 83 is an aluminum coating or similar barrier
layer that is coated on the inside of both HIPS liners; i.e., the
entire inside is coated with the aluminum or similar barrier layer.
The coating is formed by a PVD process. Coating 83 prevents gas
from entering the liner and getting into the interior of the door
structure. Although a door structure is shown in this exemplary
embodiment, the inventive concept is not limited thereto and can be
applied to any refrigerator or freezer cabinet structural component
as well.
[0044] Although the above description has described and illustrated
various aspects of the present disclosure, the various aspects are
merely exemplary by nature and are not to be construed as limiting
of the inventive concept. Rather, the inventive concept of the
disclosed present disclosure is defined by the claimed subject
matter.
* * * * *