Folding approach to create a 3d vacuum insulated door from 2d flat vacuum insulation panels

Abstract

An appliance door includes a vacuum insulated structure having a plurality of core sections that are folded to form an ice and/or water dispensing cavity on an outer side of the appliance door. The vacuum insulated door structure may be positioned between an outer door member and a door liner.

The invention claimed is: 
     
         1 . A method of making a vacuum insulated appliance structure, the method comprising:
 providing a board structure comprising a plurality of core material boards that are foldably interconnected along V-shaped grooves;   positioning the board structure in an envelope comprising substantially impermeable barrier material, whereby the board structure and the envelope form a subassembly;   forming a vacuum around the subassembly in a vacuum to evacuate the inside of the envelope;   sealing the envelope;   folding the core material boards relative to one another to form a three dimensional vacuum insulated structure having a cavity with an opening;   positioning the three dimensional vacuum insulated structure between a liner and an outer skin; and   securing the outer skin to the liner.   
     
     
         2 . The method of  claim 1 , wherein:
 the three dimensional vacuum insulated structure includes five sides defined by core material boards, the three dimensional vacuum insulated structure further including upright lower and upper portions below and above, respectively, the opening of the cavity.   
     
     
         3 . The method of  claim 2 , including:
 forming an access opening through at least one of the core material boards, defining the cavity;   positioning a dispensing unit that dispenses at least ice and/or liquid water above the cavity whereby ice and/or liquid water from the dispensing unit travels through the access opening into the cavity.   
     
     
         4 . The method of  claim 3 , wherein:
 the plurality of core material boards comprises seven core material boards, and wherein:   the subassembly includes five of the core material boards positioned adjacent one another to form a row, and two of the core material boards are positioned on opposite sides of the row.   
     
     
         5 . The method of  claim 4 , wherein:
 the row comprises first, second, third, fifth, sixth and seventh core material boards, and wherein the two core material boards positioned on opposite sides of the row comprise third and fourth core material boards; and wherein;   the first and second core material boards are foldably interconnected along a fold line, the second and third core material boards are foldably interconnected along a fold line, the third and fourth core material boards are foldably interconnected along a fold line, the fourth and fifth core material boards are foldably interconnected along a fold line, the fifth and sixth core material boards are foldably interconnected along a fold line, and the sixth and seventh core material boards are foldably interconnected along a fold line.   
     
     
         6 . The method of  claim 1 , including:
 positioning at least one preformed spacer between the three dimensional vacuum insulated structure and the outer skin.   
     
     
         7 . The method of  claim 1 , wherein:
 adjacent core material boards are interconnected by compressed material at bases of the V-shaped grooves.   
     
     
         8 . The method of  claim 7 , including:
 the V-shaped grooves are formed by pressing a V-shaped forming tool into a surface of a sheet of core material board.   
     
     
         9 . The method of  claim 1 , including:
 interconnecting adjacent core material boards utilizing tape to form the board structure.   
     
     
         10 . The method of  claim 1 , wherein:
 the subassembly is generally flat prior to folding the core material boards relative to one another.