Vacuum insulated panel for counteracting vacuum bow induced deformations
A vacuum insulated cabinet structure includes first and second cover members having pre-deformed portions and perimeter portions. The perimeter portions of the first and second cover members are disposed along first and second planar levels and the pre-deformed portions of the first and second cover members include portions thereof extending outwardly relative to the first and second planar levels. A thermal bridge interconnects the first cover member and the second cover member at the perimeter portions thereof to define an insulating cavity therebetween. The insulating cavity is a sealed cavity having a vacuum drawn therefrom. The pre-deformed portions of the first and second cover members move inwardly towards the first and second planar levels under a force of the vacuum within the insulating cavity.
1. A method of making a vacuum insulated cabinet structure, the method including the steps of:
providing an exterior wrapper having a receiving cavity defined by a plurality of sidewalls;
outwardly deforming one or more of the sidewalls of the exterior wrapper, such that the sidewalls of the exterior wrapper include pre-deformations outwardly extending beyond a first desired planar level;
providing at least one liner having a plurality of sidewalls defining a compartment;
outwardly deforming one or more of the sidewalls of the at least one liner, such that the sidewalls of the at least one liner include pre-deformations outwardly extending beyond a second desired planar level;
positioning the least one liner in the receiving cavity of the exterior wrapper;
providing a thermal bridge interconnecting the exterior wrapper and the at least one liner to define an insulating cavity therebetween having a first interior volume;
drawing a vacuum on the insulating cavity;
collapsing the pre-deformations of the sidewalls of the exterior wrapper to draw the sidewalls of the exterior wrapper into alignment with the first desired planar level;
collapsing the pre-deformations of the sidewalls of the at least one liner to draw the sidewalls of the at least one liner into alignment with the second desired planar level; and
decreasing the first interior volume of the insulating cavity to a second interior volume.
2. The method of claim 1 , wherein the sidewalls of the exterior wrapper and the sidewalls of the at least one liner are comprised of a sheet metal material.
3. The method of claim 2 , wherein the sidewalls of the exterior wrapper and the sidewalls of the at least one liner are pre-deformed in a sheet metal stamping process.
4. The method of claim 3 , wherein the stamping process provides weakened portions of the sidewalls of the exterior wrapper and the sidewalls of the at least one liner.
5. The method of claim 1 , further comprising the step of:
sealing the insulating cavity to maintain the vacuum.
6. The method of claim 1 , wherein the step of drawing the vacuum includes drawing a vacuum of less than 10 mbar within the insulting cavity.
7. The method of claim 1 , including the step of:
introducing an insulation material into the insulting cavity.
8. The method of claim 7 , wherein the insulation material includes one of fumed silica, glass beads, processed rice husks, and a combination thereof.
9. The method of claim 7 , wherein the insulation material has a thermal conductivity of 5 mW/m·K or lower.