Patent ID: 12196237

DETAILED DESCRIPTION OF EMBODIMENTS

For purposes of description herein the terms “upper,” “lower,” “right,” “left,” “rear,” “front,” “vertical,” “horizontal,” and derivatives thereof shall relate to the device as oriented inFIG.1. However, it is to be understood that the device 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 inventive 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.

As illustrated inFIGS.1-4, reference numeral10generally refers to a multi-layer encapsulation system that is disposed within a channel12of a trim breaker14for securing an inner liner16and an outer wrapper18to the trim breaker14for forming a structural cabinet20for an appliance22. According to the various embodiments, the appliance22can include the inner liner16and the outer wrapper18. The trim breaker14includes the channel12that receives at least one of the liner edge24of the inner liner16and the wrapper edge26of the outer wrapper18. A composite encapsulation system10is included that hermetically seals an insulating cavity28defined between the outer wrapper18and the inner liner16. The composite encapsulation system10includes a base adhesive30and an outer adhesive32. The base and outer adhesive30,32each define, respectively, structural adhesive components and sealing adhesive components. According to various aspects of the device, the base and outer adhesives30,32are separated by a medial buffer layer34. The medial buffer layer34is adapted to prevent direct contact between the base and the outer adhesives30,32. Accordingly, it is contemplated that the outer adhesive32is injected, poured, sprayed or otherwise disposed over the medial buffer layer34to be physically separated from direct contact with the base adhesive30by the medial buffer layer34.

The medial buffer layer34that is included within aspects of the composite encapsulation system10is typically included where the base adhesive30and outer adhesive32have chemical compositions that are not compatible in the event of direct contact. In such an embodiment, the chemical make-up of the base adhesive30may react negatively with the outer adhesive32, and/or vice versa. In order to prevent this negative deterioration of either of the base or outer adhesives32, the medial buffer layer34is included to prevent this physical contact. The inclusion of the medial buffer layer34allows for the use of a wide range of adhesives and/or sealing materials that may not otherwise be able to be used due to incompatible chemistries of the various materials. Additionally, the medial buffer layer34may also provide additional resistance to permeability for the entire composite encapsulation system10, while also preventing negative chemical reactions between the base adhesive30and outer adhesive32.

Referring now toFIGS.1-8, it is contemplated that the channel12can include a wrapper channel42that receives the liner edge24of the inner liner16. The channel12can also include a separate wrapper channel42that is adapted to receive the wrapper edge26of the outer wrapper18. In various alternative aspects, it is contemplated that the trim breaker14can include a single channel12that receives both the wrapper edge26of the outer wrapper18and the liner edge24of the inner liner16. In these various embodiments, it is contemplated that the inner liner16and outer wrapper18are disposed within the channel12while the base adhesive30is in a substantially viscous and uncured state44. In this manner, the base adhesive30has a sufficient viscosity to form around the wrapper edge26and the liner edge24such that the base adhesive30engages both sides46of the inner liner16and outer wrapper18. Accordingly, the base adhesive30occupies at least a portion of the insulating cavity28between the inner liner16and the outer wrapper18. This surrounding engagement provides a robust engagement of the base adhesive30with the inner liner16and outer wrapper18. The outer adhesive32can then be applied over the base adhesive30. Typically, the outer adhesive32is applied after the base adhesive30defines a cured state48. Typically, the base adhesive30forms a structural adhesive component for the composite encapsulation system10. After the outer adhesive32cures, the outer adhesive32can define a sealing adhesive component of the composite encapsulation system10. Additionally, the outer adhesive32can provide an additional structural component to provide a more robust attachment between the trim breaker14and the inner liner16and outer wrapper18. It should be understood that the base and outer adhesives30,32can each provide structural and sealing functionality to the composite encapsulation system10.

Referring again toFIGS.2-8, the medial buffer layer34can be in the form of a solid member that is disposed over the base adhesive30, which is, typically, in the cured state48. It is also contemplated that the medial buffer layer34can be a spray-type material that is disposed over the base adhesive30in the cured state48. In this manner, the base adhesive30is adapted to engage a lower surface60of the medial buffer layer34. Depending upon the nature of the medial buffer layer34and the state (cured state48or uncured state44) of the base adhesive30, the base adhesive30may bond to the lower surface60of the medial buffer layer34. Alternatively, the medial buffer layer34may rest upon, in a substantially surface-type engagement with, the base adhesive30. The outer adhesive32is then applied to the upper surface62of the medial buffer layer34such that the outer adhesive32bonds, adheres to, or otherwise engages the upper surface62of the medial buffer layer34to define the composite encapsulation system10. Once the base adhesive30and the outer adhesive32are in the cured state48, the base adhesive30, the medial buffer layer34and the outer adhesive32cooperatively define the composite encapsulation system10that provides a substantially monolithic adhesive having an increased resistance to permeability of gas72and vapor over that of each of the individual components by themselves.

Referring again toFIGS.2-8, it is contemplated that the elastic base can be an epoxy-type adhesive. The base adhesive30, which is typically elastic, can also be in the form of other adhesives that can include, but are not limited to, acrylics, cyanoacrylates, polyurethanes, silicones, hybrids or combinations thereof, and other similar adhesives that may have a good barrier performance to block gas72(such as oxygen) and water vapor from permeating therethrough. This base adhesive30is adapted to encapsulate the plastic and metal joint area of the trim breaker14and inner liner16and outer wrapper18and provide hermetic sealing for the vacuum structure. The base adhesive30also provides a robust bond strength between the plastic of the trim breaker14and the metals of the outer wrapper18and/or the inner liner16.

As discussed above, the medial buffer layer34could be a solid member that is placed on top of the base adhesive30. It is contemplated that this medial buffer layer34can be in the form of a metallic or non-metallic sheet, a metallic-type coating, a non-metallic-type coating, various coatings that can be deposited through physical vapor deposition, spray-coatings, polymer-based coatings, elastomeric coatings, rubberized coatings, combinations thereof, and other similar barrier-type materials that can maintain the base adhesive30separate from the outer adhesive32.

Referring again toFIGS.2-8, the outer adhesive32can take the form of any one of various adhesives. Typically, the outer adhesive32will have elastic properties to allow for minimal movement of the inner liner16and outer wrapper18with respect to the trim breaker14. These adhesives can include, but are not limited to, silicone adhesives, polyurethane adhesives, polymer-type materials, other silicone-type materials, combinations or hybrids thereof, and other similar materials that have a certain amount of elasticity to allow for movement of the inner liner16and outer wrapper18with respect to the trim breaker14during formation of the cabinet20and also during the life of the appliance22. It is contemplated that the outer adhesive32has a robust attachment strength and also permeation resistance, such that if the base adhesive30experiences a de-lamination phenomenon, the outer adhesive32may be sufficient to the at least partial vacuum within the insulating cavity28. Additionally, the outer adhesive32can define a protective layer that limits permeation to prevent significant amounts of humidity, gas72and vapor from reaching the base adhesive30.

According to the various embodiments as exemplified inFIGS.2-8, it is contemplated that an insulation material68can be disposed within the insulating cavity28. Additionally, at least one of the inner liner16and outer wrapper18can include a gas port70that is used to express or expel gas72from the insulating cavity28. In this manner, the insulating cavity28can define an at least partial vacuum74therein for increasing the insulating functionality of the cabinet20.

Referring now toFIGS.5-10, typically, the inner liner16and outer wrapper18are disposed within the base adhesive30before the medial buffer layer34and the outer adhesive32are disposed over the base adhesive30. Accordingly, portions of the base adhesive30disposed within the insulating cavity28between the inner liner16and outer wrapper18may be substantially inaccessible. In various embodiments, the medial buffer layer34and the outer adhesive32are disposed, typically, at an outside surface80of the outer wrapper18and at an inside surface82of the inner liner16. In this manner, the medial buffer layer34and the outer adhesive32extends from an outside edge84of the trim breaker14to an outside surface80of the outer wrapper18and also from an inside edge86of the trim breaker14to an inside surface82of the inner liner16. In such an embodiment, it is contemplated that at least a portion of the insulation material68can at least partially engage the base adhesive30within the insulating cavity28. At these outer portions of the trim breaker14, the outer adhesive32is free of direct contact with the base adhesive30. In general, where the base adhesives30are chemically incompatible or at least partially incompatible, the medial buffer layer34will be installed therebetween such that the outer adhesive32is free of direct contact with the base adhesive30. To maintain the spacing and positioning of the trim breaker14and the channel12, a pedal100holds the trim breaker14in a substantially fixed position.

In various embodiments, it is contemplated that the inner liner16and/or outer wrapper18can include a dedicated port that can be used for disposing the outer adhesive32and/or the medial buffer layer34over the base adhesive30and within the insulating cavity28. Typically, the outer adhesive32and the medial buffer layer34will be disposed only proximate the exterior surface90of the cabinet20and between the trim breaker14and the inner liner16and the trim breaker14and the outer wrapper18. In this position, the composite encapsulation system10that incorporates the base adhesive30, the outer adhesive32and, in certain embodiments, the medial buffer layer34, is positioned to significantly reduce the permeation of gas72and vapor into the insulating cavity28. In turn, the composite encapsulation system10extends the duration of the at least partial vacuum74within the insulating cavity28and prolongs the life of the insulating functionality of the cabinet20.

Referring now toFIGS.1-11, having described various aspects of the composite encapsulation system10, a method400is disclosed for forming an insulating cabinet20for an appliance22. According to the method400, a base adhesive30is delivered while in an uncured state44into a channel12of a trim breaker14(step402). A liner edge24of the inner liner16is disposed into the channel12so that the adhesive base in the uncured state44surrounds both sides46of the liner edge24within the channel12(step404). A wrapper edge26of an outer wrapper18is also disposed into the channel12so that the base adhesive30in the uncured state44surrounds both sides46of the wrapper edge26within the channel12(step406). The base adhesive30is then cured (step408). An outer adhesive32can be disposed over the base adhesive30(step410). It is contemplated that the outer adhesive32covers the adhesive base and engages the outer wrapper18and inner liner16at the trim breaker14. The outer adhesive32is then cured to define the composite encapsulation system10(step412). The base adhesive30and the outer adhesive32each define structural and sealing components of the composite encapsulation system10that cooperate to reduce the permeation of gas72and vapor into the insulating cavity28of the cabinet20. According to various aspects of the method400, as exemplified inFIGS.1-11, an insulation material68can be disposed within the insulating cavity28defined between the inner liner16and the outer wrapper18(step414). Gas72can then be expressed from the insulating cavity28and the insulation material68defined within the insulating cavity28(step416). In this manner, the expression or expulsion of gas72from the insulating cavity28defines an at least partial vacuum74therein. The base adhesive30and the outer adhesive32are at least partially elastic to provide for an at least partial movement of the inner liner16and the outer wrapper18without damaging or degrading the integrity of the encapsulation system10. This movement is permitted while also maintaining the hermetic seal between the inner liner16and the trim breaker14and between the outer wrapper18and the trim breaker14.

Referring now toFIGS.1-10and12, a method500is disclosed for forming an insulating cabinet20for an appliance22. According to the method500, a base adhesive30is delivered in an uncured state44to the liner channel40and the wrapper channel42of the trim breaker14(step502). The liner edge24of the inner liner16is disposed into the liner channel40(step504). In this manner, the base adhesive30in the uncured state44and within the liner channel40is allowed to surround both sides46of the liner edge24within the liner channel40. The wrapper edge26of the outer wrapper18is disposed into the wrapper channel42(step506). Accordingly, the base adhesive30in the uncured state44which is disposed within the wrapper channel42, surrounds both sides46of the wrapper edge26within the wrapper channel42. The base adhesive30within the liner and wrapper channels40,42is cured to define a structural adhesive component and also includes a sealing function for limiting permeation of gas72and vapor into the insulating cavity28of the cabinet20(step508). Once the base adhesive30is cured, a medial buffer layer34is disposed onto at least a portion of the base adhesive30in the cured state48(step510). As discussed previously, the medial buffer layer34is included where the base adhesive30and the outer adhesive32have chemical formulations that may be at least partially incompatible and may result in degradation of one or both of the base and outer adhesives30,32. After placement of the medial buffer layer34, the outer adhesive32is disposed over the medial buffer layer34(step512).

According to the various embodiments, as exemplified inFIGS.1-10and12, typically, the outer adhesive32extends from an outside edge84of the trim breaker14to an outside surface80of the outer wrapper18and also extends from an inside edge86of the trim breaker14to an inside surface82of the inner liner16. The outer adhesive32is then cured (step514). The outer adhesive32, once cured, cooperates with the base adhesive30and the medial buffer layer34to define a composite encapsulation system10having the structural adhesive capability and also sealing capability. Each of the base adhesive30and the outer adhesive32have structural and sealing components that limit permeation of gas72and vapor into the insulating cavity28, even after a failure of one of the base and outer adhesives30,32. The combination of the base and outer adhesives30,32defines a greater resistance to permeation of gas72and vapor. Accordingly, the outer adhesive32may be adapted to include a greater resistance to degradation or delamination during exposure to the outside atmosphere surrounding the cabinet20as compared to the base adhesive30.

Referring again toFIGS.1-10and12, the method500includes a step516of disposing insulation material68within an insulating cavity28defined between an inner liner16and the outer wrapper18. The insulation material68can be disposed within an insulating cavity28during installation of the inner liner16and outer wrapper18. In such an embodiment, the insulation material68can be disposed between the inner liner16and outer wrapper18. The inner liner16, outer wrapper18and insulation material68can then be disposed as a unit into the channel12, or channels12of the trim breaker14. It is also contemplated that the insulation material68can be disposed around the inner liner16after the inner liner16has been disposed within the liner channel40of the trim breaker14. The insulation material68can then be disposed around the inner liner16and the outer wrapper18can then be disposed around the insulation material68to dispose the insulation material68within the insulating cavity28. The insulation material68can also be disposed within the insulating cavity28after the composite encapsulation system10has been fully formed and cured. In such an embodiment, one of the inner liner16and outer wrapper18can include an insulation port through which an insulating material can be poured, blown, or otherwise disposed within the insulating cavity28.

Referring again toFIGS.1-10and12, after installation of the insulation material68, gas72can be expressed from the insulating cavity28in the insulation material68defined within the insulating cavity28(step518). This expression or expulsion of gas72serves to define an at least partial vacuum74within the insulating cavity28. It is contemplated that the base and outer adhesives30,32, as well as the medial buffer layer34, can have some elastic properties, such that the composite encapsulation system10permits at least partial movement of the inner liner16and outer wrapper18while maintaining the hermetic seal between the inner liner16and the trim breaker14and between the outer wrapper18and the trim breaker14.

According to the various embodiments, it is contemplated that the composite encapsulation system10described herein can be incorporated within various appliances22and fixtures that utilize a vacuum insulation structure. Such appliances22can include, but are not limited to, refrigerators, freezers, coolers, ovens, water heaters, dishwashers, laundry appliances, combinations thereof, and other similar appliances22and fixtures disposed within household and commercial settings.

It will be understood by one having ordinary skill in the art that construction of the described device and other components is not limited to any specific material. Other exemplary embodiments of the device disclosed herein may be formed from a wide variety of materials, unless described otherwise herein.

For purposes of this disclosure, the term “coupled” (in all of its forms, couple, coupling, coupled, etc.) generally means the joining of two components (electrical or mechanical) directly or indirectly to one another. Such joining may be stationary in nature or movable in nature. Such joining may be achieved with the two components (electrical or mechanical) and any additional intermediate members being integrally formed as a single unitary body with one another or with the two components. Such joining may be permanent in nature or may be removable or releasable in nature unless otherwise stated.

It is also important to note that the construction and arrangement of the elements of the device as shown in the exemplary embodiments is illustrative only. Although only a few embodiments of the present innovations have been described in detail in this disclosure, those skilled in the art who review this disclosure will readily appreciate that many modifications are possible (e.g., variations in sizes, dimensions, structures, shapes and proportions of the various elements, values of parameters, mounting arrangements, use of materials, colors, orientations, etc.) without materially departing from the novel teachings and advantages of the subject matter recited. For example, elements shown as integrally formed may be constructed of multiple parts or elements shown as multiple parts may be integrally formed, the operation of the interfaces may be reversed or otherwise varied, the length or width of the structures and/or members or connector or other elements of the system may be varied, the nature or number of adjustment positions provided between the elements may be varied. It should be noted that the elements and/or assemblies of the system may be constructed from any of a wide variety of materials that provide sufficient strength or durability, in any of a wide variety of colors, textures, and combinations. Accordingly, all such modifications are intended to be included within the scope of the present innovations. Other substitutions, modifications, changes, and omissions may be made in the design, operating conditions, and arrangement of the desired and other exemplary embodiments without departing from the spirit of the present innovations.

It will be understood that any described processes or steps within described processes may be combined with other disclosed processes or steps to form structures within the scope of the present device. The exemplary structures and processes disclosed herein are for illustrative purposes and are not to be construed as limiting.

It is also to be understood that variations and modifications can be made on the aforementioned structures and methods without departing from the concepts of the present device, and further it is to be understood that such concepts are intended to be covered by the following claims unless these claims by their language expressly state otherwise.

The above description is considered that of the illustrated embodiments only. Modifications of the device will occur to those skilled in the art and to those who make or use the device. Therefore, it is understood that the embodiments shown in the drawings and described above is merely for illustrative purposes and not intended to limit the scope of the device, which is defined by the following claims as interpreted according to the principles of patent law, including the Doctrine of Equivalents.