Whirlpool Corporation

Ashish Nigam

Shayta Roy

Abhay Naik

Gustavo Frattini

Devidas Balu Raskar

Nicole M Ernat

Lakshya J Deka

Subrata Shannigrahi

Anna Jedralski

A low-density insulating material for use in a vacuum insulated structure for an appliance includes a plurality of microspheres that includes a plurality of leached microspheres. Each leached microsphere has an outer wall and an interior volume. The outer wall has a hole that extends through the outer wall and to the interior volume. A binder engages outer surfaces of the plurality of leached microspheres, wherein the binder cooperates with the plurality of leached microspheres to form at least one microsphere aggregate. The interior volume of each leached microsphere defines an insulating space that includes an insulating gas. The insulating space of each leached microsphere is at least partially defined by the binder.

Microsphere-based insulating materials for use in vacuum insulated structures

An appliance cabinet includes a structural envelope having an exterior surface and an interior surface that defines an insulating cavity, wherein the insulating cavity defines an at least partial vacuum. A plurality of silica-based agglomerates are disposed within the insulating cavity, wherein each agglomerate of the plurality of silica-based agglomerates includes silica-based powder insulation material that is water-densified and is at least substantially free of a material binder. A secondary insulation material is disposed within interstitial spaces defined between the plurality of silica-based agglomerates, wherein the plurality of silica-based agglomerates defines an interior structure that resists inward compressive forces exerted as a result of the at least partial vacuum defined within the insulating cavity.

Wet granulation for manufacture of thermal insulation material

A filling system for a vacuum insulated structure is provided having a powder processor including a hopper having an inner hopper wall and an outer hopper wall. The filling system also includes a vacuum insulated structure having a liner positioned inside a wrapper, a trim breaker coupling an outer liner edge and an outer wrapper edge to form a shell defining an internal cavity with at least one gas permeable feature positioned in the internal cavity configured to help apply a vacuum. A loading port is positioned on a surface of the shell. The powder processor loads the shell with a heated and at least partially degassed vacuum insulation material through the loading port while a vacuum is applied to the shell through the at least one gas permeable feature.

Processing of core material in a vacuum insulated structure

An auger feeder includes a hopper having an inner hopper wall and an outer hopper wall where the inner hopper wall includes an air permeable surface. A space is positioned between the inner and outer hopper walls. A heater is coupled to an outside edge of the inner hopper wall or a n outside edge of the outer hopper wall while a feed screw is positioned along an inside edge of the inner hopper wall. The auger feeder additionally includes an evacuator coupled to a vacuum port that is positioned in the outer hopper wall. The auger feeder also includes an aperture exit positioned at a bottom of the inner and outer hopper walls.

Vacuum assisted and heated auger feeder for achieving higher packing efficiency of powder insulation materials in vacuum insulated structures

A vacuum insulated compartment includes an outer wrapper and an inner liner that is sealed to the outer wrapper. A cavity is defined therebetween. The cavity includes a negative pressure. An insulation material is disposed in the cavity. A getter assembly is disposed in the cavity and includes a primary getter material that is deposited on a plate. A cover layer is deposited over the primary getter material on the plate. A vessel is nested within the primary getter material. A secondary getter material is disposed within the vessel. A protective enclosure is disposed around the getter assembly.

Getter activation under vacuum

A method for preparing a vacuum insulated panel includes forming an internal cavity between a liner and a wrapper and preparing a filler material to be disposed in the internal cavity. The filler material includes a first part and a second part and is prepared by treating a surface of the first part. A coating is applied to the surface of the first part with a chemical having a first charge. The coating forms a first surface charge on the surface of the first part. The method further includes mixing the first part with the second part forming the filler material. The second part includes a material having a second surface charge opposite the first surface charge.

Method for improved insulation and filler materials

An auger feeder includes a hopper having an inner hopper wall and an outer hopper wall where the inner hopper wall includes an air permeable surface. A space is positioned between the inner and outer hopper walls. A heater is coupled to an outside edge of the inner hopper wall or an outside edge of the outer hopper wall while a feed screw is positioned along an inside edge of the inner hopper wall. The auger feeder additionally includes an evacuator coupled to a vacuum port that is positioned in the outer hopper wall. The auger feeder also includes an aperture exit positioned at a bottom of the inner and outer hopper walls.

The disclosure provides for a method for preparing a vacuum insulated panel. The method comprises forming an internal cavity between a liner and a wrapper and preparing filler material to be disposed in the internal cavity. The filler material comprises a first part and a second part. Preparing the filler material comprises treating a surface of the first part, wherein the treating prepares the surface to receive a coating comprising a first charge. The preparing further comprises coating the surface of the first part with a chemical comprising a first charge. The coating forms a first surface charge on the surface of the first part. The method further comprises mixing the first part with the second part forming the filler material. The second part comprises a material having a second surface charge opposite the first surface charge.

Method and structure for improved insulation and filler materials

A structural cabinet for an appliance includes an outer wrapper and an inner liner defining an insulating cavity therebetween. A first insulating structural layer is disposed against an inner surface of the outer wrapper. A second insulating structural layer is disposed against the inward surface of the inner liner. A core insulating material is disposed between the first and second structural insulating layers, wherein the first and second insulating structural layers reinforce the outer wrapper and inner liner, respectively, and resist deflection when the core insulating material is in a compressed state within the insulating cavity.

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St. Joseph, MI, United States of America

Ashish Nigam