Encapsulation system for a thermal bridge breaker-to-metal liner

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Solution Overview

Problem

Existing encapsulation systems for structural cabinets in appliances fail to provide a reliable hermetic seal between dissimilar materials like metallic liners, wrappers, and plastic thermal trim breakers, leading to inefficient heat transfer and potential structural issues due to differences in thermal expansion.

Innovation Solution

A multi-component thermal encapsulation material is used, which transitions from a pre-mix state to an application state and then a sealing state, forming a hermetic seal by surrounding the edges of the wrapper and liner within channels, allowing for elastic movement and maintaining the seal despite thermal expansion differences.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If a hermetic seal is formed between dissimilar materials (metallic liner, metallic wrapper, plastic thermal trim breaker), then thermal expansion differences cause structural issues and heat transfer inefficiency

Engineering Contradiction:

Improvehermetic seal reliabilityVSAvoidthermal expansion damage

Core Design Contradiction:

ReliabilityVSObject-affected harmful factors

Solution Approach 1:

The encapsulation material changes its physical parameters through a multi-state transformation process. In the pre-mix state, components are separate and rigid. In the application state, mixed components create a uncured material with high flexibility and flowability. In the sealed state, the cured material provides structural integrity while maintaining elastic properties to accommodate thermal expansion, thus resolving the contradiction between seal reliability and thermal expansion compatibility

Inventive Principle:

Principle #35Parameter changes

Solution Approach 2:

The system uses a multi-component encapsulation material where distinct components (such as resin and hardener) are combined in the application state to create a composite structure. This composite material integrates the benefits of different materials: adhesion to dissimilar surfaces, flexibility during curing, and elastic recovery to handle thermal expansion, thereby achieving reliable hermetic sealing without structural damage

Inventive Principle:

Principle #40Composite materials

2Strength

If rigid encapsulation material is used to form a hermetic seal, then the seal is strong but thermal expansion differences cause structural issues

Engineering Contradiction:

Improveseal strengthVSAvoidthermal expansion accommodation

Core Design Contradiction:

StrengthVSAdaptability or versatility

Solution Approach 1:

The encapsulation material exhibits dynamic properties through its multi-state transformation. The transition from rigid pre-mix components to a flexible uncured state, and finally to a cured state with elastic dynamics, allows the material to adapt to thermal expansion movements while maintaining seal integrity. The elastic nature in the sealed state enables the seal to dynamically respond to thermal stresses without compromising strength

Inventive Principle:

Principle #15Dynamics

3Reliability

If multi-component thermal encapsulation material is used, then hermetic seal is achieved with thermal expansion accommodation, but the process complexity increases

Engineering Contradiction:

Improvehermetic seal qualityVSAvoidencapsulation process complexity

Core Design Contradiction:

ReliabilityVSDevice complexity

Solution Approach 1:

The encapsulation material is segmented into distinct components that are separately prepared and then combined. This segmentation allows each component to be optimized for specific functions (adhesion, flexibility, curing) while the overall system achieves reliable hermetic sealing. The segmented approach also enables controlled mixing and application, managing process complexity through modular component delivery

Inventive Principle:

Principle #1Segmentation

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 provides a sturdy, hermetic seal that allows for the generation of a partial vacuum within the cabinet, reducing heat transfer between metallic and plastic components and accommodating thermal expansion, thus enhancing the structural integrity and insulation efficiency of the appliance.

Implementation Method 1

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

Methodology Applied

Scientific EffectChemical reaction: Chemical Bonding

Implementation Method 2

Methodology Applied

Scientific EffectThermal expansion: Thermal Expansion

Data Source

PatentUS12055344B2Encapsulation system for a thermal bridge breaker-to-metal liner

Publication Date: 2024.08.06 WHIRLPOOL CORP

AI summary

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, and an insulation material disposed within an insulating cavity defined therebetween. A multi-component thermal encapsulation material defines pre-mix, application and sealing states. The pre-mix state is defined by the 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.