APPLIANCE DOOR WITH VACUUM INSULATED OUTER DOOR
A refrigerator includes an insulated cabinet structure and a cooling system. A door assembly includes a perimeter structure that is movably mounted to the insulated cabinet structure and an outer door that is movably mounted to the perimeter structure whereby the outer door can be moved between open and closed positions relative to the perimeter structure when the perimeter structure is in its closed position The outer door may comprise a vacuum insulated structure including porous core material disposed in a cavity of the outer door.
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Refrigerators typically include an insulated cabinet structure, an electrically powered cooling system, and one or more doors that are movably mounted to the cabinet structure to provide user access to the refrigerated space within the refrigerator. Known cabinet structures may include a sheet metal outer wrapper and a polymer inner liner. Closed-cell foam or other suitable insulating material is disposed between the metal wrapper and the polymer liner. Refrigerator doors often have a similar construction and include a sheet metal outer wrapper, polymer inner liner, and foam disposed between the sheet metal wrapper and polymer liner.
Refrigerator doors may include one or more shelves that are configured to hold food and/or other items such as jugs of milk and/or other types of cans, jars, and the like. These items may be quite heavy, and refrigerator doors and hinges are typically therefore rigid and structurally sound to support the loads.
SUMMARY OF THE INVENTIONOne aspect of the present invention is a refrigerator including an insulated cabinet structure defining a refrigerated interior space having an access opening that permits user access to the refrigerated interior space. A cooling system cools the refrigerated interior space. A door assembly selectively closes off at least a portion of the access opening. The door assembly includes a first door structure or perimeter structure that is movably mounted to the insulated cabinet structure for movement between open and closed positions. The perimeter structure defines an outer perimeter and a door opening through a central portion of the perimeter structure. At least one shelf is supported by the perimeter structure in the door opening. The door assembly further includes a vacuum insulated second or outer door that is movably mounted to the perimeter structure whereby the outer door can be moved between open and closed positions relative to the perimeter structure when the perimeter structure is in its closed position. The outer door thereby selectively closes off the door opening without moving the perimeter structure or the shelf. The vacuum insulated outer door includes inner and outer layers that are spaced apart to define a vacuum cavity. Porous core material may be disposed in the vacuum cavity.
These and other features, advantages, and objects of the present invention will be further understood and appreciated by those skilled in the art by reference to the following specification, claims, and appended drawings.
For purposes of description herein, the terms “upper,” “lower,” “right,” “left,” “rear,” “front,” “vertical,” “horizontal,” and derivatives thereof shall relate to the invention as oriented in
With reference to
The refrigerator 1A includes a cooling system 22 that selectively cools the refrigerated compartment 12 and freezer compartment 18. The cooling system 22 may comprise a conventional electrically powered refrigeration system including a controller, sensors, compressor, condenser, and evaporator. Alternatively, the cooling system 22 may comprise thermoelectric cooling elements or other suitable devices.
With reference to
The perimeter structures 30A are mounted to the insulated cabinet structure 5 by hinges 28 or other suitable structures for rotation about vertical axes between open and closed positions. The perimeter structures 30A may include a metal outer wrapper or skin 46 and a polymer liner 48 that form a ring-shaped cavity that is at least partially filled with closed-cell polyurethane foam insulation 50 or other suitable insulating material that is disposed between the metal outer wrapper 46 and the polymer inner liner 48. The perimeters of the outer wrapper 46 and the polymer inner liner 48 may be joined/connected utilizing known techniques. One or more supports such as shelves 52A-52C extend horizontally between the upright side portions or sections 38 and 40 in or across door opening 44. Opposite ends 53 of shelves 52A-52C (
Outer doors 32A are movably mounted to the perimeter structure 30A for rotation about vertical axes by hinges 54 (
With further reference to
The vacuum insulated outer doors 32A may be constructed in various ways. For example, the core panel 76 may comprise porous filler material 80 that is disposed inside of a gas impermeable wrapper or envelope 78. Envelope 78 may comprise polymer and/or metal layers that are impermeable to gas. Various suitable envelopes are known in the art, such that the details of envelope 78 are not described in detail. The porous filler 80 may be positioned inside of the envelope 78 prior to assembly of door 32, and the filler 80 may be subject to a vacuum prior to sealing the envelope 78. The core panel 76 can then be positioned between the outer skin 66 and inner liner 68 during assembly, and the outer skin 66 and inner liner 68 can be secured along the perimeters 70 and 72, respectively utilizing adhesives, mechanical connectors, or other suitable means. In this configuration, the envelope 78 provides an airtight, gas-impermeable layer such that the outer skin 66 and inner liner 68 do not necessarily need to be impermeable, and a seal along the perimeters 70 and 72 of outer skin 66 and inner liner 68, respectively, is not necessarily required.
Door 32A may also be constructed by placing solid filler material 80 between the outer skin 66 and inner liner 68. According to this aspect of the present invention, the porous filler material 80 comprises a solid block of material that is preformed (e.g. pressed) into a shape corresponding to cavity 74, and a wrapper or envelope 78 is not required. After the solid block of porous filler 80 is positioned between the outer skin 66 and inner liner 68, the perimeters 70 and 72 are sealed together utilizing adhesive, heat-sealing processes, or the like. The cavity 74 is then subject to a vacuum to remove the air through a vacuum port such as opening 82 in liner 68. The opening 82 is then sealed using a plug or the like (not shown) such that the cavity 74 forms a vacuum.
An outer door 32A according to another aspect of the present invention may be fabricated by first assembling the outer skin or wrapper 66 with the inner liner 68, and forming an airtight seal at the perimeters 70 and 72, respectively utilizing adhesives/sealants, a heat sealing process, or other suitable process/means. Porous filler 80 in the form of loose powder such as fumed silica or other suitable material is then deposited into the cavity 74 through opening 82 or through a feeder port on the wrapper (not shown). The opening 82 is then subject to a vacuum to remove the air from cavity 74, and the opening 82 is then sealed.
Referring again to
In use, a user can grasp the handles 33A of outer doors 32A to thereby open the outer doors 32A without moving the perimeter structure 30A relative to the insulated cabinet structure 5. A user can then remove items positioned on shelves 52A-52C without moving perimeter structure 30A relative to the insulated cabinet structure 5. As shown in
With further reference to
With further reference to
In use, one or more of the outer doors 32C may be opened using handles 33C without moving perimeter structure 30C relative to the insulated cabinet structure 5 if a user needs to access items on shelves 90A-90E. Alternatively, a user can move the perimeter structure 30C relative to the insulated cabinet structure 5 by grasping handles 35C and rotating the perimeter structure 30C about hinges 28.
It will be understood that the features described in connection with the various embodiments of the present invention are not necessarily mutually exclusive. For example, a refrigerator having an insulated cabinet 5 could include combinations of perimeter structures 10A-10C and outer doors 32A-32C as required for a particular application.
Claims
1. A refrigerator, comprising:
- an insulated cabinet structure defining a refrigerated interior space having an access opening that permits user access to the refrigerated interior space;
- a cooling system that is configured to cool the refrigerated interior space;
- a door assembly that selectively closes off at least a portion of the access opening;
- wherein the door assembly includes a perimeter structure that is movably mounted to the insulated cabinet structure for movement between open and closed positions, the perimeter structure defining an outer perimeter and a door opening through a central portion of the perimeter structure to provide access to the refrigerated interior space when the perimeter structure is in a closed position, wherein the perimeter structure includes an outer wrapper and an inner liner that is secured to the outer wrapper to define a ring-shaped cavity, extending around the perimeter structure between the outer perimeter of the structure and the door opening, and wherein the ring-shaped cavity is filled with closed-cell foam insulation to form a rigid structure, wherein the perimeter structure includes oppositely facing inner and outer surfaces defining a first thickness;
- wherein the door assembly further includes at least one shelf supported by the perimeter structure, and wherein the shelf has an upwardly opening U-shape in cross section to support jugs of milk thereon, and wherein the shelf is disposed in the door opening;
- wherein the door assembly further includes a vacuum insulated outer door that is movably mounted to the perimeter structure whereby the outer door can be moved between open and closed positions relative to the perimeter structure when the perimeter structure is in its closed position to selectively close off at least a portion of the door opening without moving the least one shelf, wherein the vacuum insulated outer door includes inner and outer layers that are spaced apart to define a cavity, and wherein the cavity defines a vacuum, and wherein the inner and outer layers have outer surfaces defining a second thickness, and wherein the first thickness is significantly greater than the second thickness.
2. The refrigerator of claim 1, wherein:
- the perimeter structure is generally ring-shaped.
3. (canceled)
4. The refrigerator of claim 2, wherein:
- the door opening is quadrilateral, and wherein the outer door has a quadrilateral perimeter that is smaller than the quadrilateral door opening and the vacuum insulated door is disposed inside the door opening.
5. The refrigerator of claim 1, wherein:
- the at least one shelf extends horizontally across the door opening.
6. The refrigerator of claim 5, wherein:
- the at least one shelf defines opposite ends that are fixed to the perimeter structure.
7. The refrigerator of claim 1, wherein:
- the perimeter structure defines a ring-shaped inner side face that sealingly engages the insulated cabinet structure around the access opening, and a ring-shaped outer side face; and
- wherein the outer door sealingly engages the outer side face around the door opening.
8. The refrigerator of claim 1, wherein:
- the outer layer of the outer door comprises sheet metal, and the inner layer of the outer door comprises a polymer liner having a perimeter that is secured to a perimeter of the sheet metal of the outer layer.
9. The refrigerator of claim 8, wherein:
- the outer door includes a core panel disposed between the sheet metal outer layer and the polymer liner, wherein the core panel comprises porous core material disposed inside an airtight sheet of material forming an envelope.
10. The refrigerator of claim 9, wherein:
- the core panel is adhesively bonded to at least one of the sheet metal and the polymer liner.
11. The refrigerator of claim 8, wherein:
- the sheet metal is sealingly connected to the polymer liner to define an airtight vacuum cavity therebetween, and including porous core material disposed between the sheet metal and the polymer liner.
12. The refrigerator of claim 1, wherein:
- the insulated cabinet structure further defines an insulated freezer compartment having a freezer opening, wherein the cooling system is configured to maintain the freezer compartment at or below freezing; and including:
- a freezer door movably mounted to the insulated cabinet structure for movement between open and closed positions to selectively close off the freezer opening, wherein the freezer door includes a vacuum insulated panel structure.
13. The refrigerator of claim 12, wherein:
- the freezer door includes a ring-shaped perimeter structure defining a freezer door opening therethrough and having non-porous foam insulation disposed within the perimeter structure; and
- wherein the freezer door includes an outer freezer door comprising a vacuum insulated panel, wherein the outer freezer door is movably mounted to the perimeter structure of the freezer door to selectively close off the freezer door opening.
14. The refrigerator door of claim 1, wherein:
- the vacuum insulated outer door is pivotably mounted to the perimeter structure and rotates about a vertical axis.
15. The refrigerator door of claim 1, wherein:
- the door opening includes horizontally juxtaposed first and second portions;
- the vacuum insulated outer door comprises a first vacuum insulated outer door that closes off the first portion of the door opening when in its closed position; and including:
- a second vacuum insulated outer door movably mounted to the perimeter structure for movement between an open position and a closed position in which the second vacuum insulated outer door closes off the second portion of the door opening.
16. The refrigerator door of claim 1, wherein:
- the vacuum insulated outer door is pivotably mounted to the perimeter structure and rotates about a horizontal axis between its open and closed positions.
17. A refrigerator, comprising:
- an insulated cabinet structure defining a refrigerated interior space having an access opening that permits user access to the refrigerated interior space;
- a door assembly that selectively closes off at least a portion of the access opening;
- wherein the door assembly includes a perimeter structure that is movably mounted to the insulated cabinet structure for movement between open and closed positions, the perimeter structure defining a first outer perimeter and a door opening through a central portion of the perimeter structure, wherein the door opening is significantly smaller than the access opening, wherein the perimeter structure includes an outer wrapper and an inner liner that is secured to the outer wrapper to define a ring-shaped cavity extending around the perimeter structure between the outer perimeter of the structure and the door opening, and wherein the ring-shaped cavity is filled with closed-cell foam insulation;
- wherein the door assembly further includes at least one shelf supported by the perimeter structure, and wherein the shelf is disposed in the door opening;
- wherein the door assembly further includes a vacuum insulated outer door that is movably mounted to the perimeter structure whereby the outer door can be moved between open and closed positions relative to the perimeter structure when the perimeter structure is in its closed position to selectively close off at least a portion of the door opening, wherein the vacuum insulated outer door defines a second perimeter that is significantly smaller than the first perimeter.
18. The refrigerator of claim 17 wherein:
- the perimeter structure includes at least one shelf extending across the door opening.
19. The refrigerator of claim 17, wherein:
- the perimeter structure defines a vertical outer side face, and includes a handle on the outer side face.
20. The refrigerator of claim 19, wherein:
- the vacuum insulated outer door defines a second vertical outer side face, and includes a handle on the second vertical outer side face.
21. The refrigerator door of claim 1, wherein:
- the inner and outer layers of the vacuum insulated door are planar, and wherein the vacuum insulated door is constructed without shelves.
Type: Application
Filed: Mar 5, 2015
Publication Date: Sep 8, 2016
Applicant: WHIRLPOOL CORPORATION (Benton Harbor, MI)
Inventors: Lakshya Deka (Mishawaka, IN), Abhay Naik (Stevensville, MI)
Application Number: 14/639,617