Multi-layer encapsulation system for joint sealing of vacuum insulated cabinets
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Solution Overview
Problem
Existing insulation structures for appliances face challenges in achieving hermetic sealing and preventing chemical incompatibility between adhesives, leading to permeability and degradation issues in vacuum insulated structures.
Innovation Solution
A multi-layer encapsulation system with a base adhesive, an outer adhesive, and a medial buffer layer that separates them to prevent direct contact and chemical reactions, allowing for the use of incompatible adhesives and enhancing permeation resistance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If a single adhesive is used for sealing the insulating cavity, then the device complexity is reduced, but the hermetic sealing performance and resistance to gas/vapor permeation deteriorate
Solution Approach 1:
The encapsulation system is divided into multiple functional layers: a first adhesive layer for structural bonding, a barrier layer for chemical incompatibility prevention and enhanced sealing, and a second adhesive layer for additional sealing. This segmentation allows each layer to perform its specific function optimally, achieving hermetic sealing without excessive complexity.
Solution Approach 2:
The encapsulation system uses composite material construction with multiple adhesive types and a barrier layer combined together. This composite structure provides both structural integrity and hermetic sealing performance, resolving the contradiction between simple structure and reliable sealing.
2Adaptability or versatility
If incompatible adhesives are used directly in contact, then the adhesive selection flexibility increases, but chemical reactions occur leading to degradation and loss of sealing functionality
Solution Approach 1:
A barrier layer is introduced as an intermediary between incompatible adhesive layers. This barrier layer prevents direct chemical contact between adhesives that would otherwise react and degrade, allowing flexible adhesive selection while maintaining chemical stability. The barrier layer acts as a mediator that enables the use of diverse adhesive materials without compromising composition stability.
3Reliability
If a multi-layer encapsulation system with barrier layer is used, then the resistance to gas and vapor permeation increases, but the manufacturing process complexity increases
Solution Approach 1:
The manufacturing process is segmented into distinct steps: applying the first adhesive, placing the barrier layer, and applying the second adhesive. This segmentation makes the complex multi-layer system manageable through standardized, sequential manufacturing operations, reducing the practical complexity despite the enhanced permeation resistance.
4Ease of manufacture
If a single sealing composition is used, then the ease of manufacture is improved, but the hermetic sealing and prevention of chemical incompatibility deteriorate
Solution Approach 1:
The sealing system uses composite materials comprising multiple adhesive layers and a barrier layer. While this increases material complexity, each component can be applied using standard adhesive application techniques, maintaining ease of manufacture while achieving superior hermetic sealing integrity through the composite structure.
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 provides a robust, hermetic seal with increased resistance to gas and vapor permeation, extending the life of the vacuum insulation and allowing for a wide range of adhesive materials to be used, while maintaining structural and sealing functionality.
Implementation Method 1
a base adhesive and an outer adhesive, each defining a structural component and a sealing component
Implementation Method 2
a multi-layer encapsulation system with a base adhesive, an outer adhesive, and a medial buffer layer that separates them to prevent direct contact and chemical reactions, allowing for the use of incompatible adhesives and enhancing permeation resistance
Data Source
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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.