Encapsulation system for a vacuum insulated structure using an elastic adhesive and barrier coating
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Solution Overview
Problem
Vacuum insulation structures in appliances face challenges in maintaining a hermetic seal due to permeability issues with existing adhesives, allowing oxygen and water vapor to penetrate and compromise the insulation's effectiveness.
Innovation Solution
A composite encapsulation system comprising a base elastic adhesive, such as polyurethane or silicone-based adhesives, combined with an outer barrier coating like polyvinylidene chloride or aluminum, which forms a structural adhesive and sealing component to hermetically seal the insulation cavity between the outer wrapper, inner liner, and trim breaker, reducing permeability through the application of a barrier coating.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a traditional adhesive is used to seal the insulation cavity, then the bonding strength is sufficient, but the adhesive allows oxygen and water vapor to penetrate through, compromising the vacuum integrity
Solution Approach 1:
The patent applies a composite encapsulation system consisting of an elastic adhesive base combined with a barrier coating layer. The adhesive provides structural bonding while the barrier coating (such as aluminum, polyvinylidene chloride, or other low-permeability materials) provides resistance to oxygen and water vapor penetration. This composite structure resolves the contradiction by combining the strengths of both materials: the adhesive ensures robust bonding between components, while the barrier coating prevents harmful permeation, thereby maintaining vacuum integrity without sacrificing bonding strength.
2Reliability
If a rigid sealing material is used to hermetically seal the insulation cavity, then the seal integrity is improved, but the flexibility and robust bonding between components is reduced
Solution Approach 1:
The sealing function is segmented into two distinct layers: an elastic adhesive base layer and a barrier coating layer. The adhesive base layer maintains flexibility and provides robust bonding between components, while the barrier coating layer provides the hermetic seal integrity. This segmentation allows each layer to perform its specialized function without compromising the other, resolving the contradiction between rigidity for sealing and flexibility for bonding.
Solution Approach 2:
The composite encapsulation system combines an elastic adhesive material with a barrier coating material to achieve both flexibility and hermetic sealing. The elastic adhesive provides movement accommodation and robust bonding, while the barrier coating provides the impermeable seal. This composite approach resolves the contradiction by integrating the complementary properties of both materials in a single encapsulation system.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The solution significantly reduces oxygen and water vapor transmission rates, maintaining the vacuum integrity and insulating capability of the appliance, while allowing for flexibility and robust bonding between components.
Implementation Method 1
A barrier coating is disposed over the adhesive base. The barrier coating covers the adhesive base and engages the outer wrapper and inner liner at the trim breaker... significantly reduces oxygen and water vapor transmission rates
Data Source
AI summary
An appliance includes an outer wrapper, an inner liner, a trim breaker having a channel that receives at least one of a wrapper edge of the outer wrapper and a liner edge of the inner liner and a composite encapsulation system including a base elastic adhesive and an outer barrier coating. The base elastic adhesive and the outer barrier coating define a structural adhesive that hermetically seals an insulation cavity defined between the outer wrapper and the inner liner.