Patent Description:
The relevant prior art documents are <CIT>, <CIT>, <CIT>, <CIT>, <CIT>, <CIT>, <CIT>, <CIT> and <CIT>.

According to the present invention a vacuum insulated structure for an appliance in accordance with claim <NUM> includes a trim breaker defining a first groove and a second groove. A first panel is disposed within the first groove and coupled to the trim breaker. A second panel is disposed within the second groove and coupled to the trim breaker. An adhesive is disposed within the first and second grooves and coupled to the first and second panels, respectively. The trim breaker includes a polyethylene terephthalate copolyester resin and has a water vapor transmission rate of less than <NUM> cc. mm/m<NUM>/day/atm.

Further, like numerals in the description and drawings represent like elements.

The terms "including," "comprises," "comprising," or any other variation thereof, are intended to cover a non-exclusive inclusion, such that a process, method, article, or apparatus that comprises a list of elements does not include only those elements but may include other elements not expressly listed or inherent to such process, method, article, or apparatus. An element preceded by "comprises a. " does not, without more constraints, preclude the existence of additional identical elements in the process, method, article, or apparatus that comprises the element.

The terms "substantial," "substantially," and variations thereof as used herein are intended to note that a described feature is equal or approximately equal to a value or description. For example, a "substantially planar" surface is intended to denote a surface that is planar or approximately planar. Moreover, "substantially" is intended to denote that two values are equal or approximately equal. In some embodiments, "substantially" may denote values within about <NUM>% of each other, such as within about <NUM>% of each other, or within about <NUM>% of each other.

Referring to <FIG>, reference numeral <NUM> generally designates a vacuum insulated structure for an appliance <NUM>. The insulating structure <NUM> includes a trim breaker <NUM> that defines a first groove <NUM> and a second groove <NUM>. The first groove <NUM> and the second groove <NUM> are spaced from another defining a cavity <NUM> therebetween. A first panel <NUM> is disposed within the first groove <NUM> and coupled to the trim breaker <NUM>. A second panel <NUM> is disposed within the second groove <NUM> and coupled to the trim breaker <NUM>. An adhesive <NUM> is disposed within the first and second grooves <NUM>, <NUM> and coupled to the first and second panels <NUM>, <NUM>, respectively. The trim breaker <NUM> comprises polyethylene terephthalate copolyester resin (<NUM>), which in some embodiments could be a glycol-modified polyethylene terephthalate copolyester resin (<NUM>). In some examples, the trim breaker <NUM> has a heat deflection temperature of at least <NUM>° Celsius.

Referring again to <FIG>, it is contemplated that the vacuum insulated structure (<NUM>) according to claim <NUM> may be in the form of a vacuum insulated structural cabinet or a vacuum insulated panel that may be used as an insulation member for the appliance <NUM>. The vacuum insulated structure <NUM> includes the first panel <NUM> and the second panel <NUM>, which may alternatively be referred to as a liner and a wrapper, respectively. Hereinafter, the first panel <NUM> is referred to as the liner <NUM>, and the second panel <NUM> is referred to as the wrapper <NUM>. The wrapper <NUM> and the liner <NUM>, coupled to the trim breaker <NUM>, define the insulating cavity <NUM> in which one or more insulation materials <NUM> may be disposed. It is generally contemplated that the insulation materials <NUM> are glass-type materials. However, it is also contemplated that the insulation materials <NUM> may be a carbon-based powder, silicon oxide-based materials, insulating gasses, and other standard insulation materials <NUM> as known in the art; such materials are described more fully below. The insulation materials <NUM> substantially fill the insulating cavity <NUM> forming a substantially continuous layer between the liner <NUM> and the wrapper <NUM>.

In addition, an at least partial vacuum <NUM> is defined within the insulating cavity <NUM>, where the at least partial vacuum <NUM> defines a pressure differential <NUM> between an exterior <NUM> of the vacuum insulated structure <NUM> and the insulating cavity <NUM>. This pressure differential <NUM> serves to define an inward compressive force <NUM> that is exerted upon both the wrapper <NUM> and the liner <NUM> and tends to bias the wrapper <NUM> and the liner <NUM> toward the insulating cavity <NUM> of the vacuum insulated structure <NUM>. The at least partial vacuum <NUM> within the insulating cavity <NUM> also tends to cause gas to infiltrate into the insulating cavity <NUM> from an area outside of the appliance <NUM>. This infiltration of gas is sometimes referred to as gas permeation.

With continued reference to <FIG>, the vacuum insulated structure <NUM> as described may be used in a variety of locations in the appliance <NUM>. By way of example, not limitation, the glass structures, such as the glass trim breaker <NUM> or the adhesive <NUM> of the vacuum insulated structure <NUM> may be used in conduits and access ports <NUM>, for running electrical wiring, refrigeration, and water pipes, within the wall of the vacuum insulated structure <NUM>, a mullion <NUM> of the appliance <NUM>, door panels <NUM>, and other parts of the appliance <NUM> in which it may be advantageous to resist gas permeation.

Referring now to <FIG> more particularly, as depicted in the form of a structural cabinet, the wrapper <NUM> has a three-dimensional shape such that a plurality of panels define a central cavity <NUM>. Correspondingly and as depicted, the liner <NUM> has a plurality of surfaces defining an inner cavity <NUM>. It is generally contemplated that the liner <NUM> is received within the central cavity <NUM> of the wrapper <NUM>, thus partially defining the insulating cavity <NUM>. Additionally, the wrapper <NUM> and the liner <NUM> include inner surfaces <NUM> and outer surfaces <NUM> and may be made from a material at least partially resistant to bending, biasing, or otherwise being formed in response to the inward compressive force <NUM>. These materials for the liner <NUM> and the wrapper <NUM> may include, but are not limited to, metals, polymers, metal alloys, combinations thereof, and other similar substantially rigid materials that can be used for vacuum insulated structures within appliances. It is contemplated that the liner <NUM> and the wrapper <NUM> may also be used to form a vacuum insulated panel. In such constructions, the liner <NUM> is referred to as the first panel, and the wrapper <NUM> is referred to as the second panel, as stated above.

Referring now to <FIG>, it is contemplated that in addition to the first and second grooves <NUM>, <NUM>, the trim breaker <NUM> may define a third groove <NUM>. It is generally contemplated that the trim breaker <NUM> defines at least one groove, which may include the first, second, and third grooves <NUM>, <NUM>, <NUM>. The first and second grooves <NUM>, <NUM> are configured to receive the liner <NUM> and the wrapper <NUM>, respectively, to define the vacuum insulated structure <NUM>. Additionally, the first groove <NUM> may alternatively be referred to as an inner groove, and the second groove <NUM> may be alternatively referred to as an outer groove. Further, the third groove <NUM> may be referred to as a central groove. Hereinafter, the first, second, and third grooves <NUM>, <NUM>, <NUM> are referred to as the inner, outer, and central grooves <NUM>, <NUM>, <NUM>, respectively.

In addition, the trim breaker <NUM> has a receiving surface <NUM> and a solid surface <NUM>. It is generally contemplated that, along with the central groove <NUM>, the inner and outer grooves <NUM>, <NUM> are defined by the receiving surface <NUM> of the trim breaker <NUM>, such that the liner <NUM> and the wrapper <NUM> are received by the inner and outer grooves <NUM>, <NUM>, respectively. The inner and outer grooves <NUM>, <NUM> are filled with the adhesive <NUM> configured to couple the liner <NUM> and the wrapper <NUM> to the trim breaker <NUM>. Moreover, the inner and outer grooves <NUM>, <NUM> include interior portions <NUM> that contact with and receive the adhesive <NUM> to secure the liner <NUM> and the wrapper <NUM> to the trim breaker <NUM>. The central groove <NUM> may have a shallower depth than the inner and outer grooves <NUM>, <NUM>.

Referring now to <FIG>, the trim breaker <NUM> is made of a mixture <NUM> that includes a polyethylene terephthalate copolyester resin <NUM>. The mixture <NUM> may also include various flake-like particles. Such flake-like particles can include but are not limited to, mica, glass, other ceramic materials, combinations thereof, and other similar materials that can be made into fine flake-like particles or nanoflakes. In general, the flakes <NUM> may limit gas permeability through the trim breaker <NUM>. An epoxy coating <NUM> may be disposed on an outer surface of the trim breaker <NUM>. Further, the mixture <NUM> may include a plurality of glass fibers <NUM>. An exemplary polymer trim breaker having gas-blocking flakes and an epoxy coating is disclosed in <CIT>, now <CIT>. It is contemplated that the mixture <NUM> may be a homogenous mixture and that the resin <NUM> may be molded to form the trim breaker <NUM>. In some examples, the flakes <NUM> and the fibers <NUM> are omitted and the mixture <NUM> primarily employs the resin <NUM> to achieve the permeability rates described herein.

In general, the process of assembling the vacuum insulated structure <NUM> may be limited in time by a curing time associated with the adhesive <NUM>. In some examples, the curing time of the adhesive <NUM> is proportional to the temperature at which the adhesive <NUM> is applied in the first and second grooves <NUM>, <NUM>. For example, for lower temperatures of the adhesive <NUM> when applied to the trim breaker <NUM>, longer curing times may result, and vice versa. Accordingly, to reduce assembly time for the vacuum insulated structure <NUM>, the curing time may be reduced by increasing the temperature at which the adhesive <NUM> is applied. Although the first and second panels <NUM>, <NUM> may have little to no deformation due to an increased adhesive application temperature, the trim breaker <NUM> may have a corresponding heat deflection temperature that is less than a heat deflection temperature of the first and second panels <NUM>, <NUM> due, at least in part, to material property differences between the first and second panels <NUM>, <NUM> and the trim breaker <NUM>. For example, the first and second panels <NUM>, <NUM> may be made of metal, whereas the trim breaker <NUM> is a polymer or plastic having a lower heat deflection temperature than metal. In addition to deformation issues during an assembly of the vacuum insulated structure that may arise from plastics having low heat deflection temperatures, temperature fluctuation of an environment of the appliance <NUM> and/or the vacuum insulated structure <NUM> after assembly may also present heating conditions that exceed the heat deflection temperature of the trim breaker <NUM> and may result in variations of a connection formed between the trim breaker <NUM> and the first and second panels <NUM>, <NUM>. For example, throughout a lifespan of the appliance <NUM> and/or the vacuum insulated structure, such as during storage of the appliance <NUM>, shipping of the appliance <NUM>, and the like, environmental conditions exceeding the heat deflection temperature of a trim breaker may be presented and expose the vacuum insulated structure to deformation.

The glycol modified polyethylene terephthalate copolyester resin <NUM> of the trim breaker <NUM> of the present disclosure may be incorporated to provide a high heat deflection temperature for the trim breaker <NUM> to limit or eliminate such deflections. For example, the trim breaker <NUM> of the present disclosure may have a heat deflection temperature that exceeds <NUM>. In other examples, the trim breaker <NUM> of the present disclosure may a have heat deflection temperature in the range of <NUM>-<NUM>. In other examples, the heat deflection temperature of the present trim breaker <NUM> is at least <NUM>. Because of the high heat deflection temperature of the trim breaker <NUM>, the adhesive <NUM>, or the epoxy, may be applied at a temperature approximating the heat deflection temperature. For example, the adhesive <NUM> may be applied at a temperature that approaches <NUM> without resulting in deflection of the trim breaker <NUM>. Accordingly, an assembly time for the vacuum insulated structure may be reduced significantly from in the range of two hours or more to <NUM> minutes or less by reducing the curing time of the adhesive <NUM> in the first and second grooves <NUM>, <NUM>. The resin <NUM> may also provide for acceptable and/or reduced permeation rates of nitrogen, oxygen, water vapor, and other gases.

Referring now to <FIG>, one unit example of the chemical makeup of a glycol modified polyethylene terephthalate copolyester resin <NUM> material employed with the trim breaker <NUM> includes a polyester bonded with another terephthalate-alcohol group. It is contemplated that other functional groups may also be included to alter properties of the resin <NUM>. It is further contemplated that the chemical structure sown in <FIG> is non-limiting.

In some examples, the trim breaker <NUM> is substantially impermeable to gases and/or liquids. In some examples, a permeation rate for oxygen through the trim breaker <NUM> is less than <NUM> cc. mm/m<NUM>/day/atm. In some examples, the permeation rate for oxygen through the trim breaker <NUM> is between <NUM> and <NUM> cc. mm/m<NUM>/day/atm. In some examples, a permeation rate for nitrogen through the trim breaker <NUM> is less than <NUM> cc. mm/m<NUM>/day/atm. In some examples, the permeation rate for nitrogen is between <NUM> and <NUM> cc. mm/m<NUM>/day/atm. In some examples, a permeation rate for water vapor transmission is less than <NUM> cc. mm/m<NUM>/day/atm. In some examples, the permeation rate for water vapor transmission is between <NUM> and <NUM> cc. mm/m<NUM>/day/atm. In general, the permeation rates described above are at <NUM> atmosphere and at room temperature. In some examples, the above rates are determined based on permeation from an interior of the vacuum-insulated structure <NUM> toward an exterior of the vacuum insulating structure <NUM>, and such rates maybe determined along a longitudinal along a longitudinal axis of the trim breaker (e.g., in a direction parallel with the first and second panels <NUM>, <NUM>).

It is contemplated that the ranges described above may be achieved via the inclusion of the glycol modified polyethylene terephthalate polyester alone or in combination with the mica flakes or glass flakes described above. For example, doping of the flakes <NUM> with the resin <NUM> may be employed to achieve the permeation rates, while the heating characteristics (e.g., a high heat deflection temperature (HDT)) of the trim breaker <NUM> may be a result of the inclusion of the particular type of copolyester resin <NUM> employed in the present disclosure. In some examples, the doping may include injecting the flakes <NUM> into the resin <NUM> at high temperature and/or pressure via solid-state diffusion techniques. The result may present a heterogenous or homogenous mixture <NUM>.

According to the various examples, the vacuum insulated structure <NUM> can be used in various appliances that can include but are not limited to, refrigerators, freezers, coolers, ovens, dishwashers, laundry appliances, water heaters, and other similar appliances and fixtures within household and commercial settings. Additionally, the insulation materials <NUM> can be a free-flowing material that can be poured, blown, compacted or otherwise disposed within the insulating cavity <NUM>. This free-flowing material can be in the form of various silica-based materials, such as fumed silica, precipitated silica, nano-sized and/or micro-sided aerogel powder, rice husk ash powder, perlite, glass spheres, hollow glass spheres, cenospheres, diatomaceous earth, combinations thereof, and other similar insulating particulate material.

According to the present invention, a vacuum insulated structure for an appliance in accordance with claim <NUM> includes a trim breaker defining a first groove and a second groove. A first panel is disposed within the first groove and coupled to the trim breaker. A second panel is disposed within the second groove and coupled to the trim breaker. An adhesive is disposed within the first and second grooves and coupled to the first and second panels, respectively, wherein the trim breaker could have a heat deflection temperature of at least <NUM>° Celsius.

According to another aspect of the present disclosure, the trim breaker comprises a glycol-modified polyethylene terephthalate copolyester.

According to another aspect of the present disclosure, the trim breaker comprises mica flakes doped in the glycol-modified polyethylene terephthalate copolyester.

According to another aspect of the present disclosure, the trim breaker has a nitrogen transmission rate of less than <NUM> cc. mm/m<NUM>/day/atm.

According to another aspect of the present disclosure, the nitrogen transmission rate is between <NUM> and <NUM> cc. mm/m<NUM>/day/atm.

According to another aspect of the present disclosure, the trim breaker has a water vapor transmission rate of less than <NUM> cc. mm/m<NUM>/day/atm.

According to another aspect of the present disclosure, the water vapor transmission rate is between <NUM> and <NUM> cc. mm/m<NUM>/day/atm.

According to another aspect of the present disclosure, the trim breaker has an oxygen transmission rate of less than <NUM> cc. mm/m<NUM>/day/atm.

According to another aspect of the present disclosure, the trim breaker has an oxygen transmission rate of between <NUM> and <NUM> cc. mm/m<NUM>/day/atm.

According to the present invention, a vacuum insulated structure according to claim <NUM> for a refrigerator includes a trim breaker that defines a first groove and a second groove spaced from one another defining a cavity therebetween. A first panel is disposed within the first groove and coupled to the trim breaker. A second panel is disposed within the second groove and coupled to the trim breaker. An adhesive is disposed within the first and second grooves and coupled to the first and second panels, respectively. The trim breaker includes a polyethylene terephthalate copolyester resin and could have a water vapor transmission rate of less than <NUM> cc. mm/m<NUM>/day/atm.

According to another aspect of the present disclosure, the polyethylene terephthalate copolyester resin includes glycol.

According to another aspect of the present disclosure, the trim breaker has a heat deflection temperature of at least <NUM>° Celsius.

According to the present invention, a vacuum insulated panel in accordance with claim <NUM> for a refrigerator includes a trim breaker that defines a first groove and a second groove spaced from one another defining a cavity therebetween. A liner is disposed in the first groove and coupled to the trim breaker. A wrapper is disposed in the second groove and coupled to the trim breaker. An adhesive is disposed within the first and second grooves and coupled to the first and second panels, respectively. The trim breaker comprises a glycol-modified polyethylene terephthalate copolyester resin and has a heat deflection temperature of at least <NUM>° Celsius.

According to another aspect of the present disclosure, the trim breaker comprises mica flakes doped in the glycol-modified polyethylene terephthalate copolyester resin.

Claim 1:
A vacuum insulated structure (<NUM>) for an appliance (<NUM>), comprising:
a trim breaker (<NUM>) defining a first groove (<NUM>) and a second groove (<NUM>);
a first panel (<NUM>) disposed within the first groove (<NUM>) and coupled to the trim breaker (<NUM>);
a second panel (<NUM>) disposed within the second groove (<NUM>) and coupled to the trim breaker (<NUM>); and
an adhesive (<NUM>) disposed within the first groove (<NUM>) and within the second groove (<NUM>) and coupled to the first panel (<NUM>) and to the second panel (<NUM>), respectively,
characterised in that the trim breaker (<NUM>) comprises a polyethylene terephthalate copolyester resin.