Whirlpool Corporation

Diptesh Mukherjee

Hua Liu

Lakshya J Deka

Mohamed Alshourbagy

Rameet Singh Grewal

Laksha J Deka

Abhay Naik

Paul B Allard

Andrea Olivani

Berhanu Allo

An insulation structure for an appliance includes a cabinet having an outer wrapper and an inner liner, with an insulating cavity defined therebetween. Insulating powder material is disposed substantially throughout the insulating cavity. An insulating gas is disposed within the insulating cavity, wherein the insulating powder material is combined with the insulating gas and cooperatively defines a suspended state and a precipitated state. The suspended state is defined by the insulating gas in motion and the insulating powder being in an aeolian suspension within the insulating gas while in motion. The precipitated state is defined by the insulating gas being in a deposition state and the insulating powder being precipitated from the insulating gas and deposited within the insulating cavity.

Insulation structure for an appliance having a uniformly mixed multi-component insulation material, and a method for even distribution of material combinations therein

A vacuum insulated structure includes a multi-layer sheet of material comprising at least one layer of barrier material that is disposed between first and second outer layers. The barrier material and the first and second outer layers comprise thermoplastic polymers or elastomeric or hybrid material systems. The multi-layer sheet of material is thermoformed or vacuum formed to form a non-planar first component having a central portion and four sidewalls extending transversely from the central portion. A second component having a central portion and four sidewalls extending transversely from the central portion is secured to the first component to form an interior space therebetween. Porous filler material is positioned in the interior space, and a vacuum is formed in the interior space by removing gasses and moisture (water vapor). The first and second components are sealed together to form a vacuum insulated structure.

Multi-layer gas barrier materials for vacuum insulated structure

A method of forming a vacuum insulated structure includes providing a multi-layer sheet of material comprising at least one layer of barrier material that is disposed between first and second outer layers. The barrier material and the first and second outer layers comprise thermoplastic polymers. The multi-layer sheet of material is thermoformed to form a non-planar first component. The first component is at least partially coated utilizing a plasma polymerization process or a physical vapor deposition process to improve the barrier properties of the first component. The method further includes securing a second component to the first component to form an interior space therebetween. Porous filler material is positioned in the interior space, and a vacuum is formed in the interior space.

Multilayer barrier materials with PVD or plasma coating for vacuum insulated structure

An insulation structure for an appliance includes a cabinet having an outer wrapper and an inner liner, with an insulating cavity defined therebetween. A plurality of hollow insulating organic/inorganic spheres is disposed within the insulating cavity, wherein a secondary insulating volume is defined between the plurality of hollow insulating organic/inorganic spheres and an interior surface of the cabinet. The interior surface of the cabinet defines the insulating cavity. An insulating fill material is disposed within the secondary insulating volume, wherein the insulating fill material and the plurality of hollow insulating organic/inorganic spheres define a substantially uniform insulating material.

A method of fabricating a vacuum insulated refrigerator structure includes injection molding a first layer of a first polymer material. A second layer of a second polymer material is injection molded over at least a portion of the first layer, and a third layer of a third polymer material is injection molded over at least a portion of the second layer to form a first component. At least one of the layers is impervious to one or more gasses. A second component is secured to the first component to form a vacuum cavity therebetween. The vacuum cavity is filled with a porous material, and the vacuum cavity is evacuated to form a vacuum. At least one of the first and third layers includes a structural reinforcement such as a rib or screw boss of increased thickness that is formed during the injection molding process.

Method of fabricating a vacuum insulated appliance structure

A method of forming a vacuum insulated refrigerator cabinet structure includes providing a multi-layer sheet of material comprising at least one layer of barrier material that is disposed between first and second outer structural layers. The barrier material and the first and second outer layers comprise thermoplastic polymers. The multi-layer sheet of material is thermoformed to form a non-planar first component having a central portion and four sidewalls extending transversely from the central portion. The method further includes securing a second component having a central portion and four sidewalls extending transversely from the central portion to the first component to form an interior space therebetween. Porous filler material is positioned in the interior space, and a vacuum is formed in the interior space. The first and second components are sealed together to form a vacuum insulated refrigerator cabinet structure.

An insulated cabinet structure includes an inner liner having a plurality of walls defining a refrigerator compartment, and an external wrapper having a plurality of walls defining a refrigerator compartment receiving area. An insulation gap is formed between the walls of the inner liner and the walls of the external wrapper. A first insulation material is positioned on a wall of the external wrapper and extends outwardly into the insulation gap to partially fill the insulation gap. The first insulation material includes a renewable resource component having a particle size in a range from about 10 microns to about 25 microns. A second insulation material is disposed in the insulation gap, such that the first insulation material and the second insulation material together substantially fill the insulation gap.

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Pune, India

Diptesh Mukherjee