Abstract: A method of forming an insulated structure for an appliance includes forming a structural enclosure having an outer wrapper and an inner liner and an insulating cavity defined therebetween, forming an insulating powder material, compacting the insulating powder material to form a pre-densified core material, disposing the pre-densified core material within an insulating cavity, wherein the insulating cavity is defined between the outer wrapper and the inner liner and expressing at least a portion of the gas contained within the insulating cavity, wherein the insulating cavity is hermetically sealed to define a vacuum insulated structure.

Abstract: A vacuum insulated structure includes a multi-layer sheet of material comprising at least one layer of barrier material that is disposed between first and second outer layers. The barrier material and the first and second outer layers comprise thermoplastic polymers or elastomeric or hybrid material systems. The multi-layer sheet of material is thermoformed or vacuum formed to form a non-planar first component having a central portion and four sidewalls extending transversely from the central portion. A second component having a central portion and four sidewalls extending transversely from the central portion is secured to the first component to form an interior space therebetween. Porous filler material is positioned in the interior space, and a vacuum is formed in the interior space by removing gasses and moisture (water vapor). The first and second components are sealed together to form a vacuum insulated structure.

Abstract: An insulation structure for an appliance includes a first vacuum insulated structure having a top and downward sides extending from the top and defining a lower connection surface. A second vacuum insulated structure having a bottom and upward sides extending from the bottom and defining an upper connection surface, and an intermediate insulation structure having a top surface and a bottom surface, wherein the top surface engages the lower connection surface of the first vacuum insulated structure to define the first insulated interior, wherein the bottom surface engages the upper connection surface of the second vacuum insulated structure to define the second insulated interior, and wherein the intermediate insulation structure includes an appliance utility path within which at least one utility for the appliance is disposed.

Abstract: A method of forming an insulated structure for an appliance includes forming a structural enclosure having an outer wrapper and an inner liner and an insulating cavity defined therebetween, forming an insulating powder material, compacting the insulating powder material to form a pre-densified core material, disposing the pre-densified core material within an insulating cavity, wherein the insulating cavity is defined between the outer wrapper and the inner liner and expressing at least a portion of the gas contained within the insulating cavity, wherein the insulating cavity is hermetically sealed to define a vacuum insulated structure.

Abstract: A method of forming a vacuum insulated refrigerator cabinet structure includes providing a multi-layer sheet of material comprising at least one layer of barrier material that is disposed between first and second outer structural layers. The barrier material and the first and second outer layers comprise thermoplastic polymers. The multi-layer sheet of material is thermoformed to form a non-planar first component having a central portion and four sidewalls extending transversely from the central portion. The method further includes securing a second component having a central portion and four sidewalls extending transversely from the central portion to the first component to form an interior space therebetween. Porous filler material is positioned in the interior space, and a vacuum is formed in the interior space. The first and second components are sealed together to form a vacuum insulated refrigerator cabinet structure.

Abstract: An ice piece making assembly and a refrigeration appliance containing the ice piece making assembly is disclosed. The ice making assembly produces ice pieces by directional freezing and includes: an ice piece forming tray having a motor engaging end, a distal end, a first side, a second side and a bottom surface, a plurality of ice piece making compartments divided by divider walls, and a plurality of heat sinks engaged to the bottom surface of the ice making compartments and deliver defrost water to a drain or defrost water catch tray positioned at at least one of the distal end and the motor engaging end; and an ice piece forming tray canopy spaced a distance above the ice piece forming tray wherein the ice piece forming tray canopy comprises a heater and a temperature sensor.

Abstract: A method of forming a vacuum insulated refrigerator cabinet structure includes providing a multi-layer sheet of material comprising at least one layer of barrier material that is disposed between first and second outer structural layers. The barrier material and the first and second outer layers comprise thermoplastic polymers. The multi-layer sheet of material is thermoformed to form a non-planar first component having a central portion and four sidewalls extending transversely from the central portion. The method further includes securing a second component having a central portion and four sidewalls extending transversely from the central portion to the first component to form an interior space therebetween. Porous filler material is positioned in the interior space, and a vacuum is formed in the interior space. The first and second components are sealed together to form a vacuum insulated refrigerator cabinet structure.

Abstract: A method of forming a vacuum insulated structure includes providing a multi-layer sheet of material comprising at least one layer of barrier material that is disposed between first and second outer layers. The barrier material and the first and second outer layers comprise thermoplastic polymers. The multi-layer sheet of material is thermoformed to form a non-planar first component. The first component is at least partially coated utilizing a plasma polymerization process or a physical vapor deposition process to improve the barrier properties of the first component. The method further includes securing a second component to the first component to form an interior space therebetween. Porous filler material is positioned in the interior space, and a vacuum is formed in the interior space.

Abstract: A method of forming an insulated structure for an appliance includes forming a structural enclosure having an outer wrapper and an inner liner and an insulating cavity defined therebetween, forming an insulating powder material, compacting the insulating powder material to form a pre-densified core material, disposing the pre-densified core material within an insulating cavity, wherein the insulating cavity is defined between the outer wrapper and the inner liner and expressing at least a portion of the gas contained within the insulating cavity, wherein the insulating cavity is hermetically sealed to define a vacuum insulated structure.

Abstract: An insulation delivery apparatus for forming an insulated appliance structure includes an insulated structure having a wrapper and a liner that define an interior cavity and a hopper having a storage bin and a delivery mechanism. The delivery mechanism delivers an insulating medium from the storage bin, through an insulation conduit and into the interior cavity. The delivery mechanism operates between idle and delivery states. A pressing mechanism is coupled with the insulation conduit and is in selective engagement with the insulated structure. The pressing mechanism operates between rest and compressing states. An inner support is in selective engagement with an outer surface of the inner liner and an operable outer support in selective engagement with the outer wrapper. The inner support and the operable outer support provide structural support to the insulated structure when the pressing mechanism is in the compressing state.

Abstract: An insulation structure for an appliance includes a first vacuum insulated structure having a top and downward sides extending from the top and defining a lower connection surface. A second vacuum insulated structure having a bottom and upward sides extending from the bottom and defining an upper connection surface, and an intermediate insulation structure having a top surface and a bottom surface, wherein the top surface engages the lower connection surface of the first vacuum insulated structure to define the first insulated interior, wherein the bottom surface engages the upper connection surface of the second vacuum insulated structure to define the second insulated interior, and wherein the intermediate insulation structure includes an appliance utility path within which at least one utility for the appliance is disposed.

Abstract: An insulation structure for an appliance includes a first vacuum insulated structure having a top and downward sides extending from the top and defining a lower connection surface. A second vacuum insulated structure having a bottom and upward sides extending from the bottom and defining an upper connection surface, and an intermediate insulation structure having a top surface and a bottom surface, wherein the top surface engages the lower connection surface of the first vacuum insulated structure to define the first insulated interior, wherein the bottom surface engages the upper connection surface of the second vacuum insulated structure to define the second insulated interior, and wherein the intermediate insulation structure includes an appliance utility path within which at least one utility for the appliance is disposed.