Insulation compaction device and method for forming an insulated structure for an appliance

Abstract

A method for forming an insulative member includes forming a wrapper for an insulating structure, the wrapper defining an insulating cavity. A predetermined amount of an insulating media is disposed into the insulating cavity, the insulating media having a pre-compaction density. The insulating media is modified to define a desired insulation density by applying a positive compression to and generating a negative compression within the insulating media during a simultaneous compression phase. At least the simultaneous compression phase is operated until the insulating media reaches a desired insulation density, the desired insulation density being greater than the pre-compaction density. The insulating cavity is sealed to maintain the desired insulation density of the insulation media within the insulating cavity to form the insulating structure.

What is claimed is: 
     
         1 . An insulation compaction device for installing insulation within an insulating structure of an appliance, the insulation compaction device comprising:
 a piston chamber having a sidewall and a base that define an internal cavity;   an operable piston selectively engaging the sidewall to selectively define a hermetic seal between the operable piston and the piston chamber, wherein the operable piston is operable to define a selected chamber volume of the internal cavity defined between the operable piston and the piston chamber;   a valve positioned proximate the base, the valve defining selective communication between the internal cavity and an exterior of the piston chamber, wherein the valve is selectively operable in a passive state to release gas disposed within the piston chamber to the exterior, wherein the passive state is defined by an equalized pressure within the piston chamber during operation of the operable piston to define the selected chamber volume; and   a pump mechanism in communication with the piston chamber via the valve to define an active state of the valve, wherein selective operation of the pump mechanism places the valve in the active state to define a chamber pressure of the internal cavity, the chamber pressure being less than the equalized pressure, and wherein the operable piston and the pump mechanism are at least one of individually operable and simultaneously operable to define a selected piston chamber environment defined by the selected chamber volume and one of the equalized pressure and the chamber pressure.   
     
     
         2 . The insulation compaction device of  claim 1 , further comprising:
 a pressure sensor in communication with the internal cavity, wherein the pressure sensor measures the chamber pressure; and   a position sensor in communication with the operable piston and the piston chamber, wherein the position sensor measures the selected chamber volume, wherein the pressure sensor and the position sensor cooperate to communicate a current piston chamber environment, wherein at least one of the operable piston and the valve are operated until the current piston chamber environment is substantially equal to the selected piston chamber environment.   
     
     
         3 . The insulation compaction device of  claim 2 , wherein the piston chamber includes an outer wrapper and an inner liner defining walls of an appliance, and wherein the internal cavity defines an insulating space within the walls. 
     
     
         4 . The insulation compaction device of  claim 3 , wherein the operable piston includes a back panel of the appliance, wherein the selected chamber volume defines a position of the back panel of the appliance relative to the outer wrapper. 
     
     
         5 . The insulation compaction device of  claim 1 , wherein the internal cavity includes an insulating media, and wherein operation of the operable piston to the selected chamber volume defines a compressed state of the insulating media within the selected piston chamber environment that corresponds to a desired insulation density. 
     
     
         6 . The insulation compaction device of  claim 1 , wherein the internal cavity includes an insulating media and wherein operation of the valve in the active state to define the chamber pressure defines a low pressure state of the insulating media within the selected piston chamber environment that corresponds to a desired insulation density. 
     
     
         7 . The insulation compaction device of  claim 6 , wherein operation of the valve in the active state in conjunction with operation of the operable piston to the chamber volume defines a compressed/low pressure state of the insulating media within the selected piston chamber environment that corresponds to the desired insulation density. 
     
     
         8 . The insulation compaction device of  claim 1 , wherein the operable piston is operated by a mechanical press. 
     
     
         9 . The insulation compaction device of  claim 6 , wherein the insulating media comprises at least one of fumed silica, rice husk and glass spheres. 
     
     
         10 . A method for forming an appliance cabinet, the method comprising steps of:
 forming an insulating cavity between an inner liner and an outer wrapper of an appliance, wherein the inner liner and the outer wrapper define walls of the appliance and the insulating cavity is partially defined between the inner liner and the outer wrapper;   disposing a gas valve within at least one of the inner liner and outer wrapper, the gas valve defining a selective communication between the insulating cavity and an exterior of the appliance;   disposing a gas pump in communication with the gas valve, wherein the gas pump is in communication with the insulating cavity via the gas valve;   providing an operable piston slidably operable against the outer wrapper, wherein selective engagement between the operable piston and the outer wrapper defines a hermetic seal;   disposing a predetermined amount of an insulation media within the insulating cavity;   disposing the operable piston within the outer wrapper;   operating at least one of the operable piston and the gas pump to define a selected insulating cavity environment that corresponds to a desired insulation density, wherein the operable piston operates to a predetermined location relative to the outer wrapper to define a selected insulating cavity volume, and wherein the gas pump is operated to define a selected insulating cavity pressure, wherein the selected insulating cavity volume and the selected insulating cavity pressure define the selected insulating cavity environment within which the insulating media is maintained at the desired insulation density.   
     
     
         11 . The method of  claim 10 , wherein when only the operable piston is operated to define the desired insulation density, the gas valve selectively operates in a passive state to release gas disposed within the insulating cavity to the exterior, wherein the passive state is defined by an equalized pressure between the insulating cavity and the exterior during operation of the operable piston to define the desired insulation density. 
     
     
         12 . The method of  claim 10 , wherein the operable piston includes a back panel of the appliance, the back panel defining the insulating cavity with the inner liner and the outer wrapper, wherein when the operable piston is operated to define the selected insulating cavity volume, the outer wrapper and the back panel are attached to maintain the hermetic seal between the back panel and the outer wrapper after the operable piston is removed. 
     
     
         13 . The method of  claim 10 , wherein when both the operable piston and the gas pump are operated to define the selected insulating cavity environment and the desired insulation density, operation of the operable piston and the gas pump can include at least one of a sequential pattern and a simultaneous pattern, wherein the sequential pattern is defined by sequential operation of the operable piston and the gas pump, and wherein the simultaneous pattern is defined by simultaneous operation of the operable piston and the gas pump. 
     
     
         14 . The method of  claim 10 , wherein the operable piston is operated by a mechanical press. 
     
     
         15 . The method of  claim 10 , wherein the insulating media comprises at least one of fumed silica, rice husk and glass spheres. 
     
     
         16 . The method of  claim 10 , further comprising steps of:
 monitoring a current pressure of the insulating cavity to determine a current insulating cavity pressure;   monitoring a current volume of the insulating cavity to determine when the current volume is substantially equal to a selected chamber volume;   determining a current density of the insulating media by comparing the predetermined amount of the insulating media to the current pressure and current volume; and   deactivating the gas pump and the operable piston when the current density is substantially equal to the desired insulation density.   
     
     
         17 . A method for forming an insulative member, the method comprising steps of: 
       forming a wrapper for an insulating structure, the wrapper defining an insulating cavity; 
       disposing a predetermined amount of an insulating media into the insulating cavity, the insulating media having a pre-compaction density; and
 modifying the insulating media to define a desired insulation density by applying a positive compression to and generating a negative compression within the insulating media during a simultaneous compression phase; 
 operating at least the simultaneous compression phase until the insulating media reaches the desired insulation density, the desired insulation density being greater than the pre-compaction density; and 
 sealing the insulating cavity to maintain the desired insulation density of the insulation media within the insulating cavity to form the insulating structure. 
 
     
     
         18 . The method of  claim 17 , wherein the positive compression is applied by an operable piston that presses the insulation media, and wherein the negative compression is generated by a gas pump that generates an at least partial vacuum within the insulating cavity. 
     
     
         19 . The method of  claim 17 , wherein the insulating structure is an appliance cabinet. 
     
     
         20 . The method of  claim 17 , wherein the insulating media comprises at least one of fumed silica, rice husk and glass spheres.