Vacuum insulated refrigerator structure, and method of routing utility lines therein

BACKGROUND OF THE INVENTION

0001Various types of insulated cabinets and doors have been developed for refrigerators and the like. Refrigerator doors and/or cabinets may comprise vacuum insulated structures having an outer wrapper that is sealed to an inner liner to form a vacuum cavity that is filled with porous material. Power and/or water lines may need to be run through the insulated structure to provide for various refrigerator components such as ice and water dispensers. However, routing utilizing lines through insulated structures may be problematic. <i>Document</i><patcit id="pcit0001" dnum="JP2004340197A"><text>JP2004-340197A</text></patcit><i>discloses a vacuum heat insulation structure for refrigerators having a through-hole, a cylindrical element having annular protrusions and a gas barrier layer being inserted into the through-hole. Document</i><patcit id="pcit0002" dnum="WO2006011112A1"><text>WO2006/011112A1 </text></patcit><i>discloses an insulated unit including a vacuum insulated cabinet and a connector enabling the transfer of mechanical and electrical lines from outside to the inner volume of the vacuum insulation cabinet. Document</i><patcit id="pcit0003" dnum="WO2011162525A2"><text>WO2011/162525A2 </text></patcit><i>discloses a refrigerator including a cabinet, a main door, a sub door installed on the main door for opening and closing the storage space of the main door and a water dispenser disposed on the sub door. Document</i><patcit id="pcit0004" dnum="US20110023532A1"><text>US2011/0023532A1 </text></patcit><i>discloses a refrigerating apparatus including a flow divider distributing liquefied refrigerant discharged from a condenser. Document</i><patcit id="pcit0005" dnum="JP6194032A"><text>JP6-194032A</text></patcit><i>discloses a refrigerator with a vacuum thermal insulated plate fixed with an adhesive agent to an inner surface of an outer box, a condensing pipe being held between the vacuum thermal insulated plate and the outer box.</i>

SUMMARY OF THE INVENTION

0002A method of routing utility lines in a vacuum insulated refrigerator structure includes forming a shell having an internal cavity. The shell has at least first and second openings to the internal cavity. The method includes forming an elongated umbilical comprising an elongated impervious tubular sleeve and an elongated core structure formed from an insulating material and defining at least two elongated internal passageways extending lengthwise along the umbilical. The method includes sealingly connecting a first end of the sleeve to the shell at the first opening, and sealingly connecting a second end of the sleeve to the shell at the second opening. A vacuum is formed in the internal cavity of the shell. The method further includes routing utility lines through the at least two elongated internal passageways whereby portions of the utility lines are disposed inside the umbilical, and opposite ends of the utility lines extend out of the opposite ends of the umbilical. The utility lines may comprise power and/or water and/or refrigerant and/or control lines or the like.

0003Another aspect of the invention is a vacuum insulated refrigerator structure including an airtight shell defining an internal vacuum cavity. The vacuum insulated refrigerator structure also includes a tubular umbilical member defining an elongated internal space and having a central portion disposed in the internal vacuum cavity. Opposite end portions of the tubular umbilical member are sealingly connected to the airtight shell. Each opposite end portion has an opening that permits access to the elongated internal space from outside of the airtight shell. The vacuum insulated refrigerator structure further includes an elongated internal core structure disposed within the elongated internal space and having opposite ends disposed adjacent the openings at the opposite ends of the tubular umbilical member. The internal core structure has at least first and second elongated internal passageways. First and second utility lines are disposed in the first and second elongated internal passageways, respectively. The first and second utility lines have opposite ends extending out of the openings at the opposite ends of the tubular umbilical member. The elongated internal core structure is formed from an insulating material.

0004These and other features, advantages, and objects of the present disclosure will be further understood and appreciated by those skilled in the art by reference to the following specification, claims, and appended drawings.

BRIEF DESCRIPTION OF THE DRAWINGS

0005<ul id="ul0001" list-style="none" compact="compact"><li><figref idref="f0001">Fig. 1</figref> is an isometric view of a refrigerator according to one aspect of the present disclosure;</li><li><figref idref="f0002">Fig. 2</figref> is a partially schematic cross sectional view of the refrigerator of <figref idref="f0001">Fig. 1</figref> taken along the line II-II;</li><li><figref idref="f0003">Fig. 3</figref> is a partially schematic fragmentary view of the refrigerator of <figref idref="f0001">Fig. 1</figref> taken along the line III-III;</li><li><figref idref="f0004">Fig. 4</figref> is a partially schematic fragmentary cross sectional view of a portion of the refrigerator of <figref idref="f0002">Fig. 2</figref> taken along the line IV-IV;</li><li><figref idref="f0005">Fig. 5</figref> is a fragmentary isomeric view of an umbilical according to one aspect of the present disclosure;</li><li><figref idref="f0006">Fig. 6</figref> is a cross sectional view of an umbilical according to another aspect of the present disclosure; and</li><li><figref idref="f0006">Fig. 7</figref> is a cross sectional view of an umbilical according to another aspect of the present invention.</li></ul>

DETAILED DESCRIPTION

0006For purposes of description herein, the terms "upper," "lower," "right," "left," "rear," "front," "vertical," "horizontal," and derivatives thereof shall relate to the disclosure as oriented in <figref idref="f0001">Fig. 1</figref>. However, it is to be understood that the disclosure may assume various alternative orientations and step sequences, except where expressly specified to the contrary. It is also to be understood that the specific devices and processes illustrated in the attached drawings, and described in the following specification, are simply exemplary embodiments of the concepts defined in the appended claims. Hence, specific dimensions and other physical characteristics relating to the embodiments disclosed herein are not to be considered as limiting, unless the claims expressly state otherwise.

0007With reference to <figref idref="f0001">Fig. 1</figref>, a refrigerator 1 according to one aspect of the present disclosure includes an insulated cabinet 2 having an insulated/refrigerated interior space 22 (<figref idref="f0002">Fig. 2</figref>) and front doors 4 and 6. Door 4 includes a handle 8, and door 6 includes a handle 10. Door 4 may be movably mounted to cabinet 2 by one or more hinges 18 (<figref idref="f0002">Fig. 2</figref>). In the illustrated example, the door 6 comprises a drawer that can be translated linearly as indicated by the arrow "A." Door 4 is rotatably mounted to the cabinet 2 by hinges or the like in a known manner, and rotates about a vertical axis as indicated by the arrow "B." Refrigerator 1 may include additional doors (not shown) in various shapes and configurations as may be required for a particular application. Refrigerator 1 may include a conventional powered cooling system (not shown) that is mounted in machine compartment 5. The cooling system may include a compressor, condenser, evaporator, and other related components that cool one or more refrigerated and/or freezer compartments. Alternatively, refrigerator 1 may include a thermoelectric cooling system.

0008An ice/water dispensing unit 12 is mounted in door 4. Power and/or water lines 14 and 16 may be operably connected to the ice/water dispenser 12 or other components. The refrigerator 1 may include a machine compartment 5 that houses various cooling system components (not shown) outside of a refrigerated compartment 22 (<figref idref="f0002">Fig. 2</figref>). As discussed in more detail below, power and/or water lines 14 and 16 may be routed through a back wall 3 of cabinet 2 utilizing an umbilical 46 (<figref idref="f0004">Fig. 4</figref>). Lines 14 and/or 16 may also comprise refrigerant lines and/or control lines.

0009With further reference to <figref idref="f0002">Fig. 2</figref>, one or more seals 20 are utilized to seal fresh food compartment 22 when door 4 is in a closed position. Ice/water dispenser 12 may be at least partially disposed within an inner structure 24 mounted to door 4. Cabinet 2 may include an outer wrapper member 26, an inner liner member 28, and vacuum core material 30. Liner 28 may be made of thermoformed polymer material or from sheet metal that is bent/formed. Similarly, door 4 may include an outer door panel wrapper member 32, inner liner 34, and vacuum core material 36. The inner and outer members 26, 28, 32, and 34 may comprise polymer or metal that is impervious to gasses to permit formation of a vacuum. As discussed in more detail below, the vacuum cores 30 and 36 may comprise a porous/permeable filler material such as silica powder 38. Filler 30 and 38 may optionally be disposed within an impermeable envelope 40. Filler 30 and/or 38 may comprise various porous/permeable filler materials such as open cell foam, glass fibers, or other suitable materials. The construction of the liners 28 and 34, wrappers 26 and 32, and vacuum core material 36 may be substantially similar to known vacuum insulated refrigerator structures. In general, an interior space 42 of door 4, and an interior space 44 of cabinet 2 comprise a sealed space which is filled with core material 30 and 38, and a vacuum is then formed in spaces 42 and 44 during the process of fabricating the cabinet 2 and door 4.

0010With further reference to <figref idref="f0003">Fig. 3</figref>, power lines 14 and/or water lines 16 are routed through a conduit such as umbilical 46 to provide water and/or power to the ice/water dispenser 12. Conduit or umbilical 46 is configured to permit routing of utility lines while maintaining a vacuum in the cabinet 2 and/or door 4. In the illustrated example, a first opening 48 is formed in a lower edge portion 50 of door 4. Wrapper 32 and liner 34 may comprise separate components that overlap along lower edge 50, and the opening 48 may extend through outer wrapper 32 and/or inner liner 34. A first fitting 52 provides an airtight seal at first end 54 of umbilical 46. A second opening 56 is provided through inner structure 24 at ice/water dispenser 12. In the illustrated example, the inner structure 24 comprises an impermeable barrier to maintain the vacuum within interior space 42. A second fitting 58 provides a sealing connection at second end 60 of umbilical 46. As discussed in more detail below, umbilical 46 includes an elongated internal passageway 62 that is generally at atmospheric pressure to thereby permit routing of power lines 14 and/or water lines 16 through the interior space 42 of door 4 without forming leaks that would otherwise destroy the vacuum in interior space 42. It will be understood that the shape and location of umbilical 46 may vary depending upon the requirements of a particular application, and the configuration of <figref idref="f0003">Fig. 3</figref> is merely an example of one possible configuration.

0011With further reference to <figref idref="f0004">Fig. 4</figref>, umbilical 46 may be routed through door 4, door 6, and/or cabinet 2 as required for a particular application. In <figref idref="f0004">Fig. 4</figref>, umbilical 46 extends through back wall 3 of cabinet 2 between machine compartment 5 and fresh food compartment 22. With reference to <figref idref="f0005">Fig. 5</figref>, umbilical 46 includes a tubular outer casing 64 and an inner spacer 66 that is disposed within the outer casing 64. Inner spacer 66 includes a plurality of elongated internal passageways 68A-68D through which utility lines such as power lines 14 and/or water lines 16 are routed. Inner spacer 66 is formed from polyurethane foam or other insulating material to prevent or reduce heat transfer to/from utility lines 14 and 16 into/from the outside of the refrigerator. The outer casing 64 may comprise a metal or plastic conduit. The outer casing 64 is preferably impermeable to air to thereby ensure that a vacuum is maintained within the interior space 42 of door 4. Thus, if outer casing 64 comprises a polymer material, casing 64 may include one or more layers of polymer that are impermeable to gasses. The spacer 66 may comprise an insulation material such as EPS or PL) foam. One or more grooves 70 may be formed in outer surface 72 of spacer 66. The umbilical 46 may have a generally circular cross sectional shape as shown in <figref idref="f0005">Fig. 5</figref>.

0012With further reference to <figref idref="f0006">Fig. 6</figref>, an umbilical 46A according to another aspect of the present disclosure has a generally oval or elliptical cross sectional shape, and includes a non-circular outer casing 64A. A non-circular (e.g. oval or elliptical) inner spacer 66A includes a plurality of internal passages 68 for routing power lines 14 and/or water lines 16.

0013With further reference to <figref idref="f0006">Fig. 7</figref>, an umbilical 46B according to another aspect of the present disclosure has a generally rectangular cross sectional shape including an outer casing 64B, and an inner spacer 66B having a plurality of passageways 68 that provide for routing of power lines 14 and/or water lines 16.

0014During assembly, the outer casing 64 is fabricated from metal or impermeable polymer material. The inner spacer 66 is then inserted into outer casing 64. The power lines 14 and/or water lines are then inserted into the passageways 68 through inner spacer 66. The opposite ends of the outer casing 64 are then sealingly attached to the outer wrapper 34 and/or inner liner 34 (<figref idref="f0004">Fig. 4</figref>). The opposite ends of outer casing 64 may be sealed to wrapper 34 and/or liner 34 utilizing adhesive sealants and/or fittings 52 and 58. Alternatively, if outer casing 64 is metal, the outer casing 64 may be welded to wrapper 32 and/or liner 34 if wrapper 32 and liner 34 are made from a compatible metal that is suitable for welding. The wrapper 32 and liner 34 are then assembled together, and silica material or powder 38 is then positioned between the wrapper 32 and liner 34. A vacuum is then applied to the interior space 42, and the interior space is then sealed to form a vacuum therein.