Multi-layer encapsulation system for joint sealing of vacuum insulated cabinets
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Solution Overview
Problem
Existing insulation structures for vacuum insulated appliances face challenges in achieving a hermetic seal due to chemical incompatibility between adhesives and permeability issues, which affect the longevity of the vacuum insulation.
Innovation Solution
A multi-layer encapsulation system utilizing a base adhesive, an outer adhesive, and a medial buffer layer that separates them to prevent chemical reactions and enhance permeation resistance, ensuring a robust and durable hermetic seal within the insulating cavity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If a single adhesive is used to seal the insulating cavity, then the sealing process is simple, but chemical incompatibility and permeability issues occur affecting vacuum insulation longevity
Solution Approach 1:
The sealing system is divided into multiple functional layers: a first adhesive layer for bonding the inner liner to the trim breaker, and a second adhesive layer for bonding the outer wrapper to the trim breaker. Each layer is optimized for its specific function, preventing chemical incompatibility while maintaining sealing integrity over time.
Solution Approach 2:
A buffer layer is introduced as an intermediary component between the first and second adhesive layers. This buffer layer prevents direct chemical interaction between incompatible adhesives, eliminating adverse reactions while maintaining the hermetic seal's structural integrity and permeation resistance.
2Reliability
If chemically incompatible adhesives are used to achieve structural and sealing functions, then the sealing performance is improved, but adverse chemical reactions occur compromising long-term durability
Solution Approach 1:
The buffer layer serves as a chemical intermediary that physically separates the first and second adhesives, preventing direct chemical interaction. This allows the use of adhesives with different chemical compositions optimized for their respective bonding functions without risking adverse reactions, thereby maintaining both sealing performance and chemical stability.
Solution Approach 2:
Each adhesive layer is selected with specific local properties: the first adhesive is optimized for bonding to the inner liner material, while the second adhesive is optimized for bonding to the outer wrapper material. The buffer layer provides localized chemical compatibility, allowing each adhesive to perform its specific function without chemical interference.
3Ease of manufacture
If adhesive layers are placed in direct contact to form a composite seal, then the manufacturing process is simplified, but permeation resistance is reduced due to chemical incompatibility
Solution Approach 1:
The buffer layer acts as a permeation barrier intermediary between the two adhesive layers. It prevents gas and vapor molecules from penetrating through the adhesive interface, thereby enhancing the overall permeation resistance of the hermetic seal while maintaining a relatively simple three-layer manufacturing process.
Solution Approach 2:
The hermetic seal is constructed as a composite system with three distinct material layers: first adhesive, buffer layer, and second adhesive. Each material is selected for its specific properties, creating a composite structure that achieves superior permeation resistance compared to single-material seals, while remaining manufacturable through standard assembly processes.
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 system effectively prevents gas and vapor permeation, maintains a partial vacuum, and prolongs the insulation functionality by using chemically compatible adhesives and a buffer layer to prevent adverse reactions, thereby enhancing the structural and sealing integrity of the composite encapsulation system.
Implementation Method 1
the base adhesive and the outer adhesive are separated by the medial buffer layer... effectively prevents gas and vapor permeation
Implementation Method 2
a base adhesive and an outer adhesive, wherein each of the base and outer adhesives define a structural component and a sealing component
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 that hermetically seals an insulating cavity defined between the outer wrapper and the inner liner. The composite encapsulation system includes a base adhesive and an outer adhesive, wherein the base adhesive defines a structural adhesive component and the outer adhesive defines a sealing adhesive component.