Insulation structure for appliances

• US 4,985,106 A
• Filed: 07/15/1988
• Issued: 01/15/1991
• Est. Priority Date: 11/17/1986
• Status: Expired due to Term

• Current Assignee: Soltech Company Limited
• Original Assignee: Soltech Company Limited
• Inventors: Nelson, Thomas E.
• Primary Examiner(s): Gallagher, John J.
• Application Number:
  US07/220,027
• Time in Patent Office: 914 Days
• Field of Search: 156/276, 156/146, 156/292, 156/227, 53/431, 53/469, 53/452, 53/474, 53/467, 428/76, 52/809, 312/229, 312/242, 312/237, 134/58 S
• US Class Current: 156/276
• CPC Class Codes: A47L 15/4209 Insulation arrangements, e.g. for sound damping or heat insulation
• CPC Class Codes: B32B 2262/101 Glass fibres
• CPC Class Codes: B32B 2307/206 Insulating
• CPC Class Codes: B32B 2315/085 Glass fiber cloth or fabric
• CPC Class Codes: B32B 2323/04 Polyethylene
• CPC Class Codes: B32B 27/12 next to a fibrous or filamentary layer
• CPC Class Codes: B32B 27/32 comprising polyolefins comprising vinyl (co)polymers or acrylic (co)polymers B32B27/30
• CPC Class Codes: B32B 3/02 characterised by features of form at particular places, e.g. in edge regions non-uniform thickness B32B3/263
• CPC Class Codes: B32B 5/24 one layer being a fibrous or filamentary layer
• CPC Class Codes: B32B 7/12 using interposed adhesives or interposed materials with bonding properties
• CPC Class Codes: E04B 1/803 with vacuum spaces included in the slab
• CPC Class Codes: E04B 1/88 Insulating elements for both heat and sound
• CPC Class Codes: E04B 2001/7687 Crumble resistant fibrous blankets or panels using adhesives or meltable fibres
• CPC Class Codes: E04B 2001/7691 Heat reflecting layers or coatings
• CPC Class Codes: E04B 2001/8414 with non-planar face, e.g. curved, egg-crate shaped
• CPC Class Codes: E04B 2001/8461 layered
• CPC Class Codes: F16L 59/026 Mattresses, mats, blankets or the like
• CPC Class Codes: F24H 1/182 Insulation
• CPC Class Codes: F24H 9/02 Casings; Cover lids; Ornamental panels
• CPC Class Codes: F25D 2201/14 using subatmospheric pressure
• CPC Class Codes: Y02A 30/242 : Slab shaped vacuum insulation
• CPC Class Codes: Y02B 40/00 : Technologies aiming at improving the efficiency of home appliances, e.g. induction cooking or efficient technologies for refrigerators, freezers or dish washers
• CPC Class Codes: Y02B 80/10 : Insulation, e.g. vacuum or aerogel insulation
• CPC Class Codes: Y10T 156/1051 : by folding
• CPC Class Codes: Y10T 428/239 : Complete cover or casing

Abstract

An insulation panel for an appliance for reducing one or more undesirable side effects due to the operation of the appliance such as noise, vibration and heat includes a first layer of enclosing material such as polyethylene or polypropylene which has greater tear resistance and configuring this first layer of enclosing material to a size and shape based upon the appliance and the area of the appliance to be covered. Next, a second layer of similar enclosing material is selected and configured so as to having a matching peripheral edge or contour with the first layer. Ultimately these two layers of enclosing material are joined together around their peripheral edges so as to define and completely enclose an interior cavity. Into this interior cavity a blanket of insulating material is dispersed of a generally uniform blanket thickness. In certain applications, the insulating material includes a binder so that the insulating material will not shift or settle relative to the enclosed cavity. The particular insulating material may either be selected for acoustical insulation, vibration dampening and/or thermal insulation. A singular purpose of the insulating material may be desired or multiple uses may be desired in which case part of the enclosed cavity may include acoustical insulation and part of the enclosed cavity may include vibration-dampening material.

Claims

1. A method of fabricating an insulation panel for use on an appliance for reducing one or more undesirable side effects caused by the operation of said appliance, said method comprising the following steps:

(a) preparing a first layer of enclosing material that corresponds to the size and shape of the appliance area to be covered;

(b) applying a first layer of loose, discrete insulation material onto said first layer of enclosing material in a blanket of substantially uniform thickness;

(c) applying an intermediate insulation pad onto said blanket of substantially uniform thickness of said discrete insulation material;

(d) applying a second layer of loose, discrete insulation material over said intermediate insulation pad in a blanket of substantially uniform thickness;

(e) introducing a binder into said insulation material;

(f) preparing a second layer of enclosing material which has a size and shape which is substantially the same as said first layer;

(g) laminating said second layer onto said blanket of insulation material; and

(h) joining the edge peripheries of said first and second layers of enclosing material so as to define an enclosed cavity.

3. The insulation panel of claim 1 wherein said first and second layers of enclosing material are fabricated of synthetic material.

4. The insulation panel of claim 3 wherein said insulation material is fiberglass.

2. An insulation panel for an appliance for reducing one or more undesirable side effects due to the operation of the appliance such as noise, vibration and heat, said insulation panel comprising:

a first layer of enclosing material having a peripheral edge of a predetermined shape;

a second layer of enclosing material having a peripheral edge of a predetermined shape which is substantially the same as the shape of the peripheral edge of said first layer of enclosing material;

an intermediate insulation pad disposed between said first and second layers;

a first portion of loose, discrete insulation material disposed between said first layer of enclosing material and said intermediate insulation pad;

a second portion of loose, discrete insulation material disposed between said second layer of enclosing material and said intermediate insulation pad;

said first and second layers being joined together along their peripheral edges so as to define an enclosed cavity, said intermediate insulation pad thereby being retained in said enclosed cavity; and

binder material dispersed in said enclosed cavity and cooperating with said first and second portions of loose, discrete insulation material so as to prevent the shifting of said discrete insulation material within said enclosed cavity.

5. The insulation panel of claim 2 wherein said first and second layers of enclosing material are fabricated of polyethylene, said insulation material is fiberglass and said binder is phenolic or sodium silicate.

6. The insulation panel of claim 2 which further includes an exterior insulation pad secured to the exterior surface of said first layer of enclosing material.

7. An insulation panel for an appliance for reducing one or more undesirable side effects due to the operation of the appliance such as noise, vibration and heat, said insulation panel comprising:

a first layer of synthetic enclosing material having a peripheral edge of a predetermined shape;

a second layer of synthetic enclosing material having a peripheral edge of a predetermined shape which is substantially the same as the shape of the peripheral edge of said first layer of enclosing material;

an intermediate insulation pad disposed between said first and second layers;

a first portion of loose, discrete insulation material disposed between said first layer of synthetic enclosing material and said intermediate insulation pad;

a second portion of loose, discrete insulation material disposed between said said second layer of synthetic enclosing material and said intermediate insulation pad; and

said first and second layers being joined together along their peripheral edges so as to define an enclosed cavity, said intermediate insulation pad thereby being retained in said enclosed cavity.

8. The insulation panel of claim 7 wherein the predetermined shape of each layer is generally T-shaped with four panels suitably sized and arranged to fit the sides, top and rear portions of a below-counter dishwasher.

9. The insulation panel of claim 7 wherein said first and second layers of synthetic enclosing material are fabricated from polyethylene.

10. The insulation panel of claim 7 wherein said insulation material is fiberglass.

11. The insulation panel of claim 10 wherein said first and second layers of synthetic enclosing material are fabricated from polyethylene.

12. In combination:

an under-the-counter, in-cabinet automatic dishwasher; and

an insulation panel cooperatively applied to said dishwasher for noise reduction, said insulation panel comprising;

a first layer of enclosing material having a peripheral edge of predetermined shape;

a second layer of enclosing material having a peripheral edge of predetermined shape which is substantially the same as the shape of the peripheral edge of said first layer of enclosing material;

an intermediate insulation pad disposed between said first and second layers;

a first portion of loose, discrete insulation material disposed between said first layer of enclosing material and said intermediate insulation pad;

a second portion of loose, discrete insulation material disposed between said said second layer of enclosing material and said intermediate insulation pad; and

said first and second layers being joined together along their peripheral edges so as to define an enclosed cavity, said intermediate insulation pad thereby being retained in said enclosed cavity.

13. The combination of claim 12 wherein said first and second layers of enclosing material are fabricated of synthetic material.

14. The combination of claim 13 wherein said insulation material is fiberglass.

15. The combination of claim 12 which further includes an exterior insulation pad secured to the exterior surface of said first layer of enclosing material.

16. The combination of claim 12 which further includes a binder material dispersed into said first and second portions of loose discrete insulation material so as to prevent the shifting of said insulation material.

17. The combination of claim 16 wherein said first and second layers of enclosing material are fabricated of polyethylene, said insulation material is fiberglass and said binder is phenolic or sodium silicate.

18. An insulation panel for an appliance for reducing one or more undesirable side effects due to the operation of the appliance such as noise, vibration and heat, said insulation panel comprising:

a first layer of enclosing material having a peripheral edge of a predetermined shape;

a second layer of enclosing material having a peripheral edge of a predetermined shape which is substantially the same as the shape of the peripheral edge of said first layer of enclosing material;

an intermediate layer of loose, discrete insulation material disposed between said first and second layers;

a panel of insulation material secured to the exterior surface of said first layer of enclosing material;

said first and second layers of enclosing material being joined together along their peripheral edges so as to define an enclosed cavity, said discrete insulation material thereby being retained in said enclosed cavity; and

binder material dispersed in said enclosed cavity and cooperating with said discrete insulation material so as to prevent the shifting of said discrete insulation material within said enclosed cavity.

19. The insulation panel of claim 18 which further includes a second panel of insulation material disposed between said first and second layers of enclosing material and arranged with loose, discrete insulation material disposed on each side thereof.

20. In combination:

an under-the-counter, in-cabinet automatic dishwasher; and

an insulation panel cooperatively applied to said dishwasher for noise reduction, said insulation panel comprising;

a first layer of enclosing material having a peripheral edge of a predetermined shape;

a second layer of enclosing material having a peripheral edge of a predetermined shape which is substantially the same as the shape of the peripheral edge of said first layer of enclosing material;

an intermediate layer of loose, discrete acoustical insulation disposed between said first and second layers;

a panel of insulation material secured to the exterior surface of said first layer of enclosing material; and

said first and second layers being joined together along their peripheral edges so as to define an enclosed cavity, said discrete acoustical insulation being retained in said enclosed cavity.

21. The combination of claim 20 which further includes a second panel of said second insulation material disposed between said first and second layers of enclosing material and arranged with loose, discrete insulation material disposed on each side thereof.

22. An insulation panel for a appliance for reducing one or more undesirable side effects due to the operation of the appliance such as noise, vibration and heat, said insulation panel comprising:

a first layer of synthetic enclosing material having a peripheral edge of a predetermined shape;

a second layer of synthetic enclosing material having a peripheral edge of a predetermined shape which is substantially the same as the shape of the peripheral edge of said first layer of enclosing material;

an intermediate insulation pad disposed between said first and second layers;

a first layer of insulation material disposed between said first layer of synthetic enclosing material and said intermediate insulation pad;

a second layer of discrete insulation material disposed between said said second layer of synthetic enclosing material and said intermediate insulation pad; and

said first and second layers of synthetic enclosing material being joined together along their peripheral edges so as to define an enclosed cavity, said intermediate insulation pad thereby being retained in said enclosed cavity.

23. In combination:

an under-the-counter, in-cabinet automatic dishwasher; and

an insulation panel cooperatively applied to said dishwasher for noise reduction, said insulation panel comprising;

a first layer of synthetic enclosing material having a peripheral edge of a predetermined shape;

a second layer of synthetic enclosing material having a peripheral edge of a predetermined shape which is substantially the same as the shape of the peripheral edge of said first layer of enclosing material;

an intermediate insulation pad disposed between said first and second layers;

a first layer of insulation material disposed between said first layer of enclosing material and said intermediate insulation pad;

a second layer of insulation material disposed between said said second layer of enclosing material and said intermediate insulation pad; and

said first and second layers of synthetic enclosing material being joined together along their peripheral edges so as to define an enclosed cavity, said intermediate insulation pad thereby being retained in said enclosed cavity.

24. In combination:

an insulation panel comprising;

a first layer of enclosing material having an eight-sided, block-T shape;

a second layer of enclosing material having an eight-sided, block-T shape; and

an intermediate layer of insulation material disposed between said first and second layers of enclosing material; and

an automatic dishwasher wherein said insulation panel is formed over and around the exterior of said dishwasher so as to apply insulation to four different surfaces of said dishwasher.