Encapsulation System for a Thermal Bridge Breaker-To-Metal Liner

The present application is a continuation of U.S. patent application Ser. No. 18/772,927 filed Jul. 15, 2024, which is a continuation of U.S. patent application Ser. No. 17/835,018 filed Jun. 8, 2022, now U.S. Pat. No. 12,055,344, which is a divisional of U.S. patent application Ser. No. 16/309,734 filed Dec. 13, 2018, now U.S. Pat. No. 11,402,149, which is a national stage entry of PCT/US2016/055161 filed Oct. 3, 2016, all of which are entitled ENCAPSULATION SYSTEM FOR A THERMAL BRIDGE BREAKER-TO-METAL LINER, the entire disclosures of which are hereby incorporated herein by reference.

The device is in the field of structural cabinets for appliances, and more specifically, an encapsulation system for attaching a metallic liner and metallic wrapper to a plastic thermal trim breaker.

In at least one aspect, an appliance includes an outer wrapper, an inner liner, a trim breaker having a wrapper channel that receives a wrapper edge of the outer wrapper and a liner channel that receives a liner edge of the inner liner. An insulation material disposed within an insulating cavity is defined between the outer wrapper, the inner liner and the trim breaker. A multi-component thermal encapsulation material defines a pre-mix state, an application state and a sealing state. The pre-mix state is defined by distinct components of the thermal encapsulation material being separated from one another, the application state defined by the distinct components combined together into an uncured state of the thermal encapsulation material, and the sealing state defined by the thermal encapsulation material disposed within the wrapper and liner channels and surrounding the wrapper and liner edges, respectively, in the sealing state that defines a hermetic seal between the trim breaker and the outer wrapper and the inner liner.

In at least another aspect, a method for forming an insulating cabinet for an appliance includes disposing distinct components of a multi-part thermal encapsulation material into respective dispensing chambers to define a pre-mix state of the thermal encapsulation material. The distinct components of the thermal encapsulation material are delivered from the respective dispensing chambers to a mixing chamber. The distinct components are mixed in the mixing chamber to define an application state of the thermal encapsulation material. The thermal encapsulation material is delivered in the application state to a liner channel and a wrapper channel of a trim breaker. A wrapper edge of an outer wrapper is disposed into the wrapper channel so that the thermal encapsulation material surrounds both sides of the wrapper edge within the wrapper channel. A liner edge of an inner liner is disposed into the liner channel so that the thermal encapsulation material surrounds both sides of the liner edge within the liner channel. The thermal encapsulation material is cured within the wrapper and liner channels to define a sealing state of the thermal encapsulation material, wherein the thermal encapsulation material in the sealing state defines a hermetic seal between the inner liner and the trim breaker and between the outer wrapper and the trim breaker.

In at least another aspect, a method for forming an insulating cabinet for an appliance includes disposing a first component and second components of a thermal encapsulation material into respective first and second dispensing chambers to define a pre-mix state of the thermal encapsulation material. The first and second components of the thermal encapsulation material are delivered from the respective first and second dispensing chambers to a mixing chamber. The thermal encapsulation material is activated by combining the first and second components within the mixing chamber to generate a chemical reaction that defines an application state of the thermal encapsulation material. The thermal encapsulation material is disposed in the application state into a liner channel and a wrapper channel of a trim breaker. A portion of an inner liner is positioned within the thermal encapsulation material in the liner channel. A portion of an outer wrapper is positioned within the thermal encapsulation material in the wrapper channel. The thermal encapsulation material is cured around the portions of the inner liner and outer wrapper within the liner and wrapper channels, respectively, wherein the cured thermal encapsulation material defines a sealing state of the thermal encapsulation material that is characterized by a hermetic seal between the inner liner and the trim breaker and between the outer wrapper and the trim breaker.

These and other features, advantages, and objects of the present device will be further understood and appreciated by those skilled in the art upon studying the following specification, claims, and appended drawings.

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 in. 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 in, reference numeralgenerally refers to a structural cabinet for an appliance, where the structural cabinetcan define a vacuum insulated structure or can house various vacuum insulated structures that add thermal functionality to the performance of the appliance. According to the various embodiments, the applianceincludes an outer wrapper, an inner linerand a trim breaker, such as a thermal trim breaker, that can be attached to define the structural cabinetfor the appliance. The trim breakerincludes a wrapper channelthat receives a wrapper edgeof the outer wrapper. The trim breakeralso includes a liner channelthat receives a liner edgeof the inner liner. An insulation materialcan be disposed within an insulating cavitydefined within the structural cabinetinbetween the outer wrapper, inner linerand trim breaker. The trim breakercan be attached to the inner linerand outer wrapperusing a multi-component thermal encapsulation materialthat defines a pre-mix state, an application state, and a sealing state. The pre-mix stateis defined by two or more distinct componentsof the thermal encapsulation materialbeing separate from one another within separate component dispensing chambersof a material delivery mechanism. The application stateof the thermal encapsulation materialis defined by the distinct componentsbeing combined together by an impelleror other mixing device within a mixing chamberof the material delivery mechanism. As the distinct componentsare mixed together in the mixing chamber, the thermal encapsulation materialdefines the uncured application stateof the thermal encapsulation material. The thermal encapsulation materialin the application stateis sufficiently fluid to allow for deposition of the thermal encapsulation material, while in the application state, to be disposed within the liner and wrapper channels,of the thermal trim breaker. The sealing stateof the thermal encapsulation materialis defined by the thermal encapsulation materialbeing disposed, in a cured state, within the liner and wrapper channels,of the thermal trim breaker. In the sealing state, the thermal encapsulation materialsurrounds the wrapper and liner edges,, respectively, and is cured to define a hermetic sealbetween the trim breakerand the outer wrapperin between the trim breakerand the inner liner.

Referring again to, it is contemplated that the thermal encapsulation materialin the sealing statecan be used to generate the hermetic sealat the trim breakerto allow for an at least partial vacuumto be generated within the insulating cavityof the structural cabinet. The at least partial vacuumcan be generated through the expression, expulsion, or other removal of gasfrom the insulating cavity. This removal of gascreates a pressure differentialbetween the atmosphere around the exteriorof the structural cabinetand the at least partial vacuumwithin the insulating cavity. This pressure differentialgenerates an inward compressive forcethat is exerted upon the outer wrapper, the inner linerand the trim breakerin the direction of the insulating cavity. As this inward compressive forceis applied on the outer wrapperand inner liner, certain bending, flexion, movement or other deflection of the inner linerand outer wrappermay occur. It is contemplated that the thermal encapsulation materialin the sealing statecan be at least partially elastic to allow for movement of the liner edgeand wrapper edgewithin the liner and wrapper channels,, respectively, without losing, damaging or otherwise degrading the hermetic sealbetween the inner linerand the trim breakerand the outer wrapperand the trim breaker. It is contemplated that use of the thermal encapsulation materialis particularly useful where the thermal trim breakeris made of a different material than the inner linerand outer wrapper. Typically, the thermal trim breakerwill be made of plastic or other similar polymer material, and the inner linerand outer wrapperwill each be made of a metallic material.

According to the various embodiments, the structural cabinetthat forms the vacuum insulated structure provides for heat transfer between the metal inner linerand the metal outer wrapperwith the vacuum insulated structure. When the plastic trim breakerseparates the inner linerand outer wrapper, these components typically have a lower heat transfer rate than would be found in a direct metal-to-metal connection between a metallic inner linerand a metallic outer wrapper. The trim breakeris installed at a front faceof the structural cabinetand is used as a cap to keep the core materials, such as various insulating materials, inside the insulating cavitybetween the inner linerand the outer wrapper. The thermal encapsulation materialused to attach the inner linerto the trim breakerand the outer wrapperto the trim breakerprovides a sturdy connection mechanism for maintaining a sealed engagement between these dissimilar materials and allowing for the generation of an at least partial vacuumwithin the insulating cavity.

Referring again to, the use of dissimilar metals in the structural cabinetbetween the metallic inner liner, the metallic outer wrapperand the plastic thermal trim breakerresults in the metallic portions of the structural cabinethaving a different coefficient of thermal expansion than that of the plastic components of the structural cabinet. The elastic nature of the thermal encapsulation materialin the sealing stateallows for these minimal expansion movements of differing degree between the typically cooler metallic inner liner, the typically warmer outer wrapperand the plastic trim breakerextending therebetween. It is contemplated that the thermal encapsulation materialcan operate to provide a sturdy hermetic sealbetween the inner linerand the trim breakerand the outer wrapperand the trim breakerunder different temperature environments typically found within and around refrigerating appliances.

According to the various embodiments, it is contemplated that the thermal encapsulation materialcan be any one of various materials that can include, but are not limited to, thermosetting polymers, thermoplastics, elastomers, combinations thereof, and other similar materials. More specifically, the thermal encapsulation materialcan include any one or more of various epoxies, silicones, polyurethanes, acrylics, polyimides, silicone polyimides, parylenes, polycyclicolefins, silicon-carbons, benzocyclobutenes, liquid crystal polymers, combinations thereof, and other similar encapsulating materials. It is contemplated that the thermal encapsulation materialcan include first and second components,, and can also include additional distinct componentsthat can be combined to form the application and sealing states,of the thermal encapsulation material.

Referring now to, it is contemplated that the liner edgecan include a plurality of liner protrusionsthat engage at least one sidewallof the liner channel. Engagement of the plurality of liner protrusionswith the liner channelserves to center the liner edgewithin the liner channel. In this manner, the centering of the liner edgewithin the liner channelserves to allow the thermal encapsulation materialto extend around and engage both of opposing first and second sides,of the liner edge. Similarly, the wrapper edgecan include a plurality of wrapper protrusionsthat engage at least one sidewallof the wrapper channel. As with the liner protrusions, engagement of a plurality of wrapper protrusionswith the wrapper channelserves to center the wrapper edgewithin the wrapper channel. As with the liner protrusionsbeing disposed within the liner channel, the use of the wrapper protrusionsserves to center the wrapper edgewithin the wrapper channelto allow the thermal encapsulation materialto be disposed around both of the opposing first and second sides,of the wrapper edge. Through the use of the liner and wrapper protrusions,, the thermal encapsulation materialcan be allowed to flow or otherwise extend around both sides of the liner edgeand the wrapper edge. Accordingly, the thermal encapsulation materialsurrounds the liner and wrapper edgesto fully encapsulate the liner edgeand wrapper edgewithin the liner and wrapper channels,, respectively.

According to the various embodiments, it is contemplated that placement of the liner and wrapper edges,within the liner and wrapper channels,, respectively, can result in the liner and wrapper edges,being free of direct contact with the thermal trim breaker. In such an embodiment, the thermal encapsulation materialcan completely surround and separate the liner and wrapper edges,from the sidewallsof the liner and wrapper channels,. Accordingly, the thermal encapsulation materialprovides an additional thermal barrier that slows the degree of thermal transfer between the metallic outer wrapperand the trim breakerand the metallic inner linerand the trim breaker.

According to aspects of the device that include the liner and wrapper protrusions,, as exemplified in, it is contemplated that the liner and wrapper protrusions,can be substantially hemispheric members that extend from opposing first and second sides,, in an alternating fashion, of each of the inner linerand outer wrapper. The hemisphere configuration of the liner and wrapper protrusions,allows for a minimal contact area between the liner edgeand the liner channeland between the wrapper edgeand the wrapper channel. This minimal degree of contact minimizes the amount of thermal transfer that may occur through the direct engagement between the inner linerand the trim breakerand the outer wrapperand the trim breaker.

Referring again to, after the inner linerand outer wrapperhave been disposed within the liner channeland wrapper channelof the trim breaker, respectively, the thermal encapsulation materialcures to form the sealing stateof the thermal encapsulation material. At this point, gascan be expressed, expelled, or otherwise removed from the insulating cavityof the structural cabinetto define an at least partial vacuumwithin the structural cabinet. It is contemplated that the insulation materialcan be disposed between the inner linerand outer wrappereither before or after the trim breakeris attached to the inner linerand the outer wrapper.

Having described various aspects of the structural cabinetusing aspects of the thermal encapsulation material, a methodis disclosed for forming an insulative structural cabinetfor an applianceusing aspects of the thermal encapsulation material. According to the method, distinct componentsof a multi-part thermal encapsulation materialare disposed into respective dispensing chambers(step). The separation of the distinct componentsof the thermal encapsulation materialdefines a pre-mix stateof the thermal encapsulation material. It is contemplated that the distinct componentsof the thermal encapsulation material, by themselves, can be substantially inert and typically do not serve as a proper adhesive or encapsulation materialfor the structural cabinet. The distinct componentsare then delivered from the respective dispensing chambersto the mixing chamberof the material delivery mechanism(step). The distinct componentshaving been disposed in the mixing chamberare then mixed by an impellerwithin the mixing chamberto define an uncured application stateof the thermal encapsulation material(step).

It is contemplated that the application stateof the thermal encapsulation materialis a substantially fluid state that allows for pouring or flowing of the thermal encapsulation materialinto the liner channeland wrapper channelof the thermal breaker. It is also contemplated that the application stateof the thermal encapsulation materialcan be a more viscous material that may be injected or otherwise compressed or molded into the liner channeland wrapper channelof the trim breaker.

According to the method, after the components of the thermal encapsulation materialhave been mixed to define the application state, the thermal encapsulation materialin the application stateis delivered to the liner channeland the wrapper channelof the trim breaker(step). The wrapper edgeof the outer wrapperis then disposed into the wrapper channelso that the thermal encapsulation materialin the application statesurrounds both sides of the wrapper edgewithin the wrapper channel(step). Similarly, the liner edgeof the inner lineris disposed into the liner channelso that the thermal encapsulation materialcan surround both sides of the liner edgewithin the liner channel(step). It is contemplated that stepsandcan be performed simultaneously or can be switched in order such that the inner lineris first placed within the liner channeland then, subsequently, the outer wrapperis placed within the wrapper channel. After the inner linerand outer wrapperare placed within the thermal encapsulation materialin the application state, the thermal encapsulation materialis then cured within the wrapper and liner channels,to define a sealing stateof the thermal encapsulation material(step). As discussed above, the thermal encapsulation materialin the sealing statedefines a hermetic sealbetween the inner linerand the trim breakerand between the outer wrapperand the trim breaker.

Referring again to, after formation of the structural cabinet, the insulation materialcan be disposed within an insulating cavitydefined between the inner linerand the outer wrapper. Gascan then be expressed from the insulating cavityand from the insulation materialdefined within the insulating cavity. This expression of gasserves to define the at least partial vacuumwithin the insulating cavity. It is contemplated that the thermal encapsulation materialin the sealing statepermits at least partial movement of the inner linerand outer wrapperduring and after the expression of gasfrom the insulating cavity. The encapsulation materialallows for this partial movement while also maintaining a hermetic sealbetween the inner linerand the trim breakerand between the outer wrapperand the trim breaker.

Referring again to, it is contemplated that the thermal encapsulation materialcan include first and second components,that are disposed within respective first and second dispensing chambers,of the material delivery mechanism, when the thermal encapsulation materialis in a pre-mix state.

Referring again to, it is contemplated that the stepof disposing the inner linerwithin the liner channelcan include centering the liner edgewithin the liner channelusing the liner protrusionsthat engage at least one sidewallwithin the liner channel. As discussed above, engagement plurality of liner protrusionswith the liner channelserves to center the liner edgewithin the liner channelsuch that the thermal encapsulation materialengages both sides of the liner edge. Similarly, the stepof disposing the wrapper edgewithin the wrapper channelincludes centering the wrapper edgewithin the wrapper channelusing the wrapper protrusions. As with the liner protrusions, the wrapper protrusionsserve to center the wrapper edgewithin the wrapper channelssuch that the thermal encapsulation materialengages both sides of the wrapper edge.

According to the various embodiments, it is contemplated that the liner and wrapper protrusions,can be hemispheric projections, dimples, detents, indents, combinations thereof, and other similar protrusions. Typically, the protrusions will be pressed or punched formations within the surface of the inner linerand outer wrappersuch that one side of the protrusion projects outward from one surface of the inner liner/outer wrapper,and the opposing side of the outward protrusiondefines an inward indentwithin the opposing first and second sides,of each of the inner liner/outer wrapper,. These geometries of the liner and wrapper protrusions,can also serve to increase the retaining force of the thermal encapsulation materialwith the inner linerand outer wrapper. Stated another way, the liner protrusiondefines the outward protrusionon a first liner surfaceand the inward indenton an opposing second liner surface. Similarly, the wrapper protrusionscan define the outward protrusionon a first wrapper surfaceand the inward indenton a second wrapper surface. In this manner, the wrapper and liner protrusions,define alternating outward protrusionsand inward indentsalong the opposing surfaces of the inner linerand outer wrapper.

Referring again to, a methodis disclosed for forming an insulating structural cabinetfor an applianceusing an aspect of the thermal encapsulation material. According to the method, first and second components,of a thermal encapsulation materialare disposed into respective first and second dispensing chambers,to define a pre-mix stateof the thermal encapsulation material(step). The first and second components,are then delivered from the respective first and second dispensing chambers,to a mixing chamber(step). The thermal encapsulation materialis activated by combining the first and second components,of the thermal encapsulation materialwithin the mixing chamberto generate a chemical reaction that defines an application stateof the thermal encapsulation material(step).

As discussed above, the application stateof the thermal encapsulation materialcan be a fluid and substantially flowable material or can be a more viscous and injectable material that can be disposed within the liner and wrapper channels,of the trim breaker.

According to the method, the thermal encapsulation materialis then disposed, while in the application state, into the liner channeland the wrapper channelof the trim breaker(step). A portion of the inner lineris then positioned, and typically centered, within the thermal encapsulation materialin the liner channel(step). A portion of the outer wrapperis then positioned and typically centered, within the thermal encapsulation materialwithin the wrapper channel(step). The thermal encapsulation materialis then cured around the portions of the inner linerand outer wrapperthat are disposed within the liner and wrapper channels,, respectively (step). The cured thermal encapsulation materialdefines the sealing stateof the thermal encapsulation materialthat is characterized by a hermetic sealbetween the inner linerof the trim breakerand between the outer wrapperof the trim breaker.

As discussed above, each of the inner linerand outer wrappercan include positioning features, typically in the form of the liner and wrapper protrusions,, that at least partially engage the liner channeland the wrapper channel, respectively. It is contemplated that the positioning features are adapted to centrally align the inner linerwithin the liner channeland to also centrally align the outer wrapperwithin the wrapper channel. According to various embodiments, it is contemplated that the positioning features can define minimal contact between the liner and wrapper edges,and the liner and wrapper channels,, respectively. It is also contemplated that the positioning features can be configured to space the liner and wrapper edges,away from the sidewallsof the liner and wrapper channels,, respectively. In such an embodiment, the liner and wrapper edges,are free of direct engagement with the liner and wrapper channels,and are fully separated by the thermal encapsulation material.

According to the various embodiments, it is contemplated that the thermal encapsulation materialcan be used in the formation of structural cabinetsfor various appliances. These appliancescan include, but are not limited to, refrigerators, freezers, coolers, ovens, dishwashers, laundry appliances, water heaters, and other similar appliancesand fixtures 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.