Gas barrier for vacuum insulation

Abstract

A gas barrier for a vacuum insulated structure of a refrigerator is provided. The gas barrier includes a plastic trim breaker; a metal outer panel a metal inner panel and insulation between the outer and inner metal panels. The gas barrier for a vacuum insulated structure further includes a PVD metal coating applied to the an inside surface of the plastic trim breaker to provide a barrier layer to the plastic trim breaker, wherein the PVD coating on the inside of the plastic trim breaker contacts the inner and outer metal outer panels to prevent heat or gas from entering the insulated structure and decreasing the effectiveness of the insulation over time.

1 . A vacuum insulated structural component of a refrigerator with a gas barrier comprising:
 a plastic trim breaker;   a metal outer panel;   a metal inner panel;   insulation between the outer and inner metal panels; and   a physical vapor deposited metal coating applied to an inside surface of the plastic trim breaker to provide a barrier layer to the plastic trim breaker,   wherein the physical vapor deposited coating on the inside of the plastic trim breaker has a thickness of at least about 0.015 mm and abuts or is adjacent to surfaces of the inner and outer metal panels to prevent heat or gas from entering the insulated structure between the inner and outer metal panels.   
     
     
         2 . The vacuum insulated structural component of a refrigerator of  claim 1 , further comprising a cabinet seal surrounded by the insulation, the outer and inner metal panels and the barrier layer on the inside of the plastic trim breaker. 
     
     
         3 . The vacuum insulated structural component of a refrigerator of  claim 1 , further comprising a flange extending inwardly from at least one of the outer and inner metal panels toward the other of the outer and inner metal panels. 
     
     
         4 . The vacuum insulated structural component of a refrigerator of  claim 3 , further comprising a flange extending from each of the outer and inner metal panels. 
     
     
         5 . The vacuum insulated structural component of a refrigerator of  claim 4 , wherein the flanges generally extend in a direction toward each other. 
     
     
         6 . The vacuum insulated structural component of a refrigerator of  claim 5 , wherein the barrier layer substantially prevents heat from entering the structure between the flanges. 
     
     
         7 . The vacuum insulated structural component of a refrigerator of  claim 3 , wherein the barrier layer prevents the space between the inner and outer metal panels from conducting heat or gas. 
     
     
         8 . The vacuum insulated structural component of a refrigerator of  claim 1 , wherein the insulation is formed from the group consisting of fumed silica, fiberglass, precipitated silica, glass microspheres or open cell polyurethane foam. 
     
     
         9 . The vacuum insulated structural component of a refrigerator of  claim 1 , wherein the barrier layer is formed of aluminum or other barrier material and the vacuum insulated structural component is a wall of the refrigerator or a door of a compartment of the refrigerator and wherein an interior of the door comprises recessed dyke walls. 
     
     
         10 . A three-dimensional vacuum insulated refrigerator liner, the three-dimensional refrigerator liner comprising:
 an interior three-dimensional liner having an internal side facing toward the interior of the refrigerator structure and a visible side which is visible to a consumer viewing the inside of the refrigerator; and   a metal coating applied by physical vapor deposition to the internal side or the visual side of the interior three-dimensional liner to form a barrier layer on the interior panel;   wherein the barrier layer prevents gas from permeating easily through the three-dimensional liner.   
     
     
         11 . The vacuum insulated three-dimensional refrigerator liner of  claim 10 , wherein the three-dimensional interior liner is constructed of HIPS or another high impact liner material. 
     
     
         12 . The vacuum insulated three-dimensional refrigerator liner of  claim 10 , wherein the liner is part of a refrigerator door. 
     
     
         13 . The vacuum insulated three-dimensional refrigerator liner of  claim 10 , wherein the three-dimensional liner is part of a refrigerator cabinet. 
     
     
         14 . The vacuum insulated three-dimensional refrigerator liner of  claim 10 , wherein the three-dimensional refrigerator liner is part of an under counter refrigerator. 
     
     
         15 . The vacuum insulated three-dimensional refrigerator liner of  claim 10 , wherein the barrier layer is formed of aluminum or other barrier material. 
     
     
         16 . The vacuum insulated three-dimensional refrigerator liner of  claim 10 , wherein the interior liner comprises bosses to provide attachment to the three-dimensional interior liner. 
     
     
         17 . The vacuum insulated three-dimensional refrigerator liner of  claim 10 , wherein the three-dimensional interior liner has ribs to provide enhanced strength to the three-dimensional interior liner. 
     
     
         18 . A refrigerator, the refrigerator comprising:
 a plastic trim breaker;   a three-dimensional liner;   a wrapper which surrounds the liner;   a back plate secured to the back of the three-dimensional liner;   insulation between the three-dimensional liner and the wrapper, and   a physical vapor deposition metal coating applied to the inside surface of the plastic trim breaker to provide a barrier layer to the plastic trim breaker,   wherein a portion of the barrier layer contacts a portion of both the three-dimensional liner and wrapper to prevent heat or gas from entering the interior of the refrigerator restructure.   
     
     
         19 . The refrigerator of  claim 18 , wherein the barrier layer is formed of aluminum. 
     
     
         20 . The refrigerator of  claim 18 , wherein the trim breaker includes recesses to receive the inner three-dimensional liner and the wrapper.