Method of making a folded vacuum insulated structure

1. A method of fabricating a vacuum insulated cabinet structure, the method comprising:

providing a first sheet of material, the first sheet comprising a metal layer and a thermoplastic polymer material, wherein the metal layer has sufficient stiffness to form a self-supporting freestanding cabinet structure when deformed;

providing a second sheet of material, the second sheet comprising a barrier layer capable of maintaining a vacuum;

positioning porous filler material between the first and second sheets;

sealing the first and second sheets together around the porous filler material to form an airtight space containing the porous filler material.

2. The method of claim 1 , including:

providing a vacuum in the airtight space; and

bending the first sheet of material to form a vacuum insulated cabinet structure.

3. A method of fabricating a vacuum insulated cabinet structure, the method comprising:

providing a first sheet of material, the first sheet comprising a metal layer and a thermoplastic polymer material on a first side of the first sheet, wherein the metal layer has sufficient stiffness to form a self-supporting freestanding cabinet structure when deformed;

providing a second sheet of material, the second sheet comprising a barrier layer capable of maintaining a vacuum;

providing a plurality of pouches having porous filler material disposed in the pouches;

positioning the pouches between the first and second sheets;

sealing the first and second sheets together to form a seal line that extends around the pouches to form an airtight space containing the pouches;

providing a vacuum in the airtight space;

bending the first sheet of material to form a vacuum insulated cabinet structure.

4. A method of fabricating a vacuum insulated cabinet structure, the method comprising:

providing a first sheet of material, the first sheet comprising a metal layer and a thermoplastic polymer material on a first side of the first sheet, wherein the metal layer has sufficient stiffness to form a self-supporting freestanding cabinet structure when deformed;

providing a second sheet of material, the second sheet comprising a barrier layer capable of maintaining a vacuum;

positioning porous filler material between the first and second sheets;

sealing the first and second sheets together around the porous filler material to form an airtight space containing the porous filler material;

providing a vacuum in the airtight space;

bending the first sheet of material to form a vacuum insulated cabinet structure.

5. The method of claim 4 , wherein:

the first and second sheets are sealed together in a vacuum chamber.

6. The method of claim 4 , wherein:

the first and second sheets are sealed together utilizing a heat sealing process that includes heating at least one of the first and second sheets of material to form a seal line that extends around the porous filler material.

7. The method of claim 4 , wherein:

the second sheet comprises at least first and second layers, the first layer comprising thermoplastic material, the second layer comprising polymer material that forms a barrier with respect to at least one of oxygen, nitrogen, and water vapor; and

the porous filler material is disposed in a plurality of pouches that are positioned between the first and second sheets prior to sealing the first and second sheets together.

8. The method of claim 4 , including:

thermoforming the second sheet of material to define a retaining structure that includes a generally planar central sidewall portion having a perimeter, and edge sidewall portions extending transversely from the perimeter, the retain structure further including a peripheral edge flange including outwardly from the edge sidewall portions.

9. The method of claim 8 , including:

positioning the peripheral edge flange in contact with the thermoplastic polymer material of the first sheet; and

heat-sealing the peripheral edge flange to the thermoplastic polymer material.

10. The method of claim 6 , including:

forming a second airtight space between the first and second sheets of material, wherein at least one seal line extends between the two airtight spaces;

bending the first sheet of material in an area between the two airtight spaces.

11. The method of claim 10 , including:

forming a third air-tight space between the first and second sheets of material;

bending the first sheet of material to a structure define at least three generally planar sidewalls.

12. The method of claim 11 , wherein:

the three panel sidewalls define spaced apart upright sidewalk and a horizontal upper wall extending between the side walls; and including:

forming a floor structure that extends between and interconnects the upright sidewalls;

securing a rear panel to the upright sidewalls, the horizontal upper wall, and the floor structure to form a primary cabinet structure that defines a forwardly-opening compartment.

13. The method of claim 12 , including:

forming a polymer liner;

positioning the polymer liner in the compartment; and

providing a thermosetting foam insulating material between the polymer liner and the primary cabinet structure.

14. The method of claim 4 , wherein:

the vacuum insulated cabinet structure comprises an insulated refrigerator cabinet structure.

15. The method of claim 4 , wherein:

the metal layer comprises low carbon steel; and

the thermoplastic polymer material is laminated to the metal layer.

16. The method of claim 4 , wherein:

providing a vacuum in the airtight space includes positioning the first and second sheets of material and the porous filler material in a vacuum chamber prior to sealing the first and second sheets together.

17. The method of claim 4 , wherein:

providing a vacuum comprising forming a vacuum in the airtight space occurs prior to bending the first sheet of material to form a vacuum insulated cabinet structure.

18. The method of claim 4 , wherein:

the porous filler material is disposed in a plurality of individual pouches that are positioned on the first side of the first sheet prior to sealing the first and second sheets together.

19. The method of claim 4 , wherein:

the first sheet of material forms an outer cabinet skin blank, the blank including an elongated portion having a generally rectangular perimeter with elongated side edges and end edges extending between the side edges, the blank defining a plurality of bend lines extending between the side edges to define a plurality of generally planar panel regions; and

bending the cabinet skin blank along the bend lines to form a vacuum insulated cabinet structure having upright outer sidewalls and a transverse wall extending between the outer sidewalls.

20. The method of claim 4 , including:

movably mounting a door to the vacuum insulated cabinet structure; and

connecting an electrically powered cooling system to the vacuum insulated cabinet structure to cool an interior space thereof.