Methods for dispensing and compacting insulation materials into a vacuum sealed structure

1. A method of forming an insulated structure for an appliance, the method comprising steps of:

forming a structural enclosure having an outer wrapper and an inner liner and an insulating cavity defined therebetween;

compacting an insulating powder material to form a pre-densified core material;

positioning the pre-densified core material within the insulating cavity, wherein the insulating cavity is defined between the outer wrapper and the inner liner; and

expressing at least a portion of a gas contained within the insulating cavity, wherein the insulating cavity is hermetically sealed to define a vacuum insulated structure.

2. The method of claim 1 , wherein the pre-densified core material is a granular insulating material.

3. The method of claim 1 , wherein the pre-densified core material is positioned between the inner liner and the outer wrapper before the outer wrapper and the inner liner are attached together.

4. The method of claim 3 , wherein the pre-densified core material is a three-dimensional core member.

5. The method of claim 4 , wherein the three-dimensional core member includes at least one binder material, wherein the at least one binder material includes at least one of cellulose, wax, polyethylene glycol, gelatin, starch, polyvinyl alcohol, polymethacrylate and sodium silicate.

6. The method of claim 4 , wherein the three-dimensional core member is bonded to at least one of the outer wrapper and the inner liner.

7. The method of claim 1 , wherein the step of compacting the insulating powder material to form the pre-densified core material is at least partially performed between the outer wrapper and the inner liner.

8. The method of claim 7 , wherein at least a portion of the step of compacting the insulating powder material includes placing the insulating powder material within the outer wrapper and compressing the insulating powder material with the inner liner.

9. The method of claim 7 , wherein the step of compacting the insulating powder material is performed while expressing at least a portion of the gas from the insulating cavity, wherein the insulating powder material directly engages the inner liner and outer wrapper.

10. The method of claim 1 , wherein the step of forming the structural enclosure includes wrapping a planar sheet around a base formation, wherein the planar sheet forms the inner liner, wherein the planar sheet remains on the base formation at least until the pre-densified core material is disposed within the insulating cavity.

11. A method of forming an insulated structure for an appliance, the method comprising steps of:

providing a base formation, wherein a surface of the base formation defines a shape of an insulating enclosure;

forming a first planar sheet to the surface of the base formation, wherein the first planar sheet includes one of an outer wrapper and an inner liner of an insulating structure;

compacting an insulating powder material to define a pre-densified core material;

positioning the pre-densified core material in engagement with the first planar sheet;

forming a second planar sheet against the pre-densified core material, wherein the second planar sheet includes the other of the outer wrapper and the inner liner;

sealing the outer wrapper and inner liner together to define an insulating cavity between the outer wrapper and the inner liner, wherein the pre-densified core material is disposed within the insulating cavity; and

expressing at least a portion of a gas contained within the insulating cavity, wherein the insulating cavity is hermetically sealed to define a vacuum insulated structure.

12. The method of claim 11 , wherein the first planar sheet formed to the surface of the base formation defines the outer wrapper, and wherein the pre-densified core material is disposed within a wrapper volume defined by an interior surface of the outer wrapper.

13. The method of claim 12 , wherein the pre-densified core material is in a form of a partially compacted granular insulating material.

14. The method of claim 12 , wherein the first planar sheet formed to the surface of the base formation defines the inner liner, and wherein the pre-densified core material is disposed against an outward facing surface of the inner liner.

15. The method of claim 14 , wherein the step of compacting the insulating powder material to define the pre-densified core material is performed while the insulating powder material is within the insulating cavity, and wherein the pre-densified core material is in a form of a three-dimensional insulating member.

16. The method of claim 15 , wherein the three-dimensional insulating member is bonded to the outward facing surface of the inner liner.

17. The method of claim 11 , wherein the vacuum insulated structure is free of a barrier film disposed in the insulating cavity.

18. A method of forming an insulated structure for an appliance, the method comprising steps of:

providing a base formation, wherein a surface of the base formation defines a shape of an insulating enclosure;

forming a first planar sheet to the surface of the base formation, wherein the first planar sheet includes an inner liner of an insulating structure;

compacting an insulating powder material to define a pre-densified core material;

positioning the pre-densified core material in engagement with an outward facing surface of the inner liner;

forming a second planar sheet against the pre-densified core material, wherein the second planar sheet defines an outer wrapper;

sealing the outer wrapper and inner liner together to define an insulating cavity between the outer wrapper and the inner liner, wherein the pre-densified core material is disposed within the insulating cavity to define the insulating structure; and

removing the insulating structure from the base formation.

19. The method of claim 18 , further comprising the step of:

expressing at least a portion of a gas contained within the insulating cavity, wherein the insulating cavity is hermetically sealed to define a vacuum insulated structure.

20. The method of claim 19 , wherein the step of expressing at least a portion of the gas is performed while the insulating structure is engaged with the base formation.