| 主权项 |
1. A method of making a vacuum insulated appliance door having an outwardly opening dispensing cavity for dispensing ice and/or liquid water, the method comprising:
providing a first core material board corresponding to an upright lower portion of an appliance door below a dispensing cavity of an appliance door; providing a second core material board corresponding to an inwardly extending lower side of a dispensing cavity of an appliance door; providing third and fourth core material boards corresponding to upright opposite sides of a dispensing cavity of an appliance door; providing a fifth core material board corresponding to an upright inner side of a dispensing cavity of an appliance door; providing a sixth core material board corresponding to an inwardly extending upper side of a dispensing cavity of an appliance door, wherein the sixth core material board has an opening therethrough; providing a seventh core material board corresponding to an upright upper portion of an appliance door above a dispensing cavity of an appliance door; positioning the first, second, third, fourth, fifth, sixth, and seventh core material boards adjacent one another inside an envelope formed from substantially impermeable barrier material to form a generally flat subassembly, wherein the envelope has at least one opening; positioning the generally flat subassembly in a vacuum chamber; forming a vacuum in the vacuum chamber; sealing the opening of the envelope in the vacuum chamber; removing the generally flat subassembly from the vacuum chamber; folding the first and second core material boards relative to one another; folding the third core material board relative to a selected one of the second and fifth core material boards; folding the fourth core material board relative to a selected one of the second and fifth core material boards; folding the fifth and sixth core material boards relative to one another; folding the sixth and seventh core material boards relative to one another; wherein the folded core material boards form a three dimensional vacuum insulated structure having a dispensing cavity defined by the second, third, fourth, fifth, and sixth core material boards, an upright lower portion below the dispensing cavity defined by the first core material board, and an upright upper portion above the dispensing cavity defined by the seventh core material board; positioning an ice and/or water dispensing unit adjacent the sixth core material board whereby, in use, ice and/or water from the dispensing unit travels downwardly through the opening through the sixth core material board; providing an outer door skin; providing a door liner; positioning the three dimensional vacuum insulated structure between the outer door skin and the door liner; and connecting the outer door skin to the door liner to form an appliance door. |
