Method and apparatus for insulating a refrigeration appliance

Abstract

A method of insulating a refrigeration appliance. The refrigeration appliance includes a case, a liner, and a five-sided, box like vacuum panel. The liner is formed to be inserted into the case forming a chamber between the liner and the case. The five sides of the vacuum panel define a cavity. The method includes in one embodiment, positioning the five-sided vacuum panel in the chamber between the case and the liner, injecting foam into the chamber, and curing the foam to attach the live sided vacuum panel to the case and the liner.

What is claimed is: 
     
         1 . A vacuum panel comprising:
 a barrier envelope;   an insulative core material positioned inside the barrier envelope; and   four side portions and a back portion defining a cavity, said four side portions and said back portion formed by said harrier envelope and said insulative core material.   
     
     
         2 . A vacuum panel in accordance with  claim 1 , wherein said barrier envelope comprises at least one of a metalized plastic and alternating layers of at least one plastic material layer and at least one metal layer. 
     
     
         3 . A vacuum panel in accordance with  claim 2 , wherein said plastic material layer comprises at least one of a polystyrene composition, a polypropylene composition, and a polyethylene terephthalate composition. 
     
     
         4 . A vacuum panel in accordance with  claim 1 , wherein the insulative core material comprises at least one of fiberglass, an open-cell foam, and an insulative powder. 
     
     
         5 . A vacuum panel in accordance with  claim 1 , wherein a pressure within said vacuum panel is below atmospheric pressure. 
     
     
         6 . A vacuum panel in accordance with  claim 5 , wherein said pressure within said vacuum panel is about 100 millibars or less. 
     
     
         7 . A vacuum panel in accordance with  claim 5 , wherein said pressure within said vacuum panel is about 10 millibars or less. 
     
     
         8 . An appliance, comprising:
 a case;   a five-sided, box like vacuum panel positioned in said case, said five-sided vacuum panel having a cavity defined by the five sides of said vacuum panel;   a liner positioned in said cavity of said five-sided vacuum panel;   a first layer of insulative foam between a first surface of said five-sided vacuum panel and said case; and   a second layer of insulative foam between a second, opposite surface of said five-sided vacuum panel and said liner.   
     
     
         9 . An appliance in accordance with  claim 8 , wherein said appliance is a refrigerator, as freezer, a combination refrigerator-freezer, or a cooler. 
     
     
         10 . An appliance in accordance with  claim 8 , wherein said five-sided vacuum panel comprises:
 a barrier envelope;   an insulative core material positioned inside the barrier envelope; and   four side portions and a back portion defining said cavity, said four side portions and said hack portion formed by said barrier envelope and said insulative core material.   
     
     
         11 . An appliance in accordance with  claim 8 , wherein said first layer of insulative foam and said second layer of insulative foam is the same insulative foam. 
     
     
         12 . An appliance in accordance with  claim 8 , wherein said first layer of insulative foam and said second layer of insulative foam each comprise a different insulative foam. 
     
     
         13 . An appliance in accordance with  claim 11 , wherein said insulative foam is selected from the group consisting of polyurethane foams and polystyrene foams.