Encapsulation system for a thermal bridge breaker-to-metal liner
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Solution Overview
Problem
Existing structural cabinet technologies face challenges in creating a hermetic seal between dissimilar materials like metallic liners, metallic wrappers, and plastic trim breakers, which affects thermal insulation and vacuum generation due to differences in material properties and thermal expansion coefficients.
Innovation Solution
A multi-component thermal encapsulation material is used, transitioning 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 under varying temperatures.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a hermetic seal is created between dissimilar materials (metallic liner, metallic wrapper, plastic trim breaker), then thermal insulation and vacuum generation are improved, but the seal reliability deteriorates due to differences in material properties and thermal expansion coefficients
Solution Approach 1:
The encapsulation material changes its physical parameters (viscosity, elasticity) in response to temperature variations. It transitions from a viscous state during application to an elastic state during thermal cycling, allowing it to accommodate expansion and contraction of dissimilar materials while maintaining seal integrity
Solution Approach 2:
The invention uses a composite encapsulation material that combines multiple properties: initial viscosity for proper filling and adhesion, followed by elastic recovery to accommodate thermal expansion. This composite material behavior resolves the contradiction between maintaining a hermetic seal and adapting to thermal expansion differences
2Strength
If a rigid seal is used between trim breaker and metallic components, then sealing strength is improved, but the seal fails under thermal expansion and contraction
Solution Approach 1:
The encapsulation material exhibits dynamic properties, transitioning from a viscous state during application (providing initial seal strength) to an elastic state during thermal cycling (providing flexibility). This dynamic behavior allows the seal to maintain strength while adapting to thermal variations
Solution Approach 2:
The encapsulation material acts as a flexible sealing layer that can deform elastically to accommodate thermal expansion and contraction of the trim breaker and metallic components, maintaining seal integrity without rigid constraints
3Reliability
If thermal encapsulation material is applied to seal wrapper and liner edges, then hermetic sealing is achieved, but the complexity of material application and curing increases
Solution Approach 1:
The encapsulation material is pre-applied to the trim breaker channels before the wrapper and liner edges are inserted. This preliminary action ensures proper material distribution and eliminates the need for complex post-assembly sealing operations
Solution Approach 2:
The encapsulation material performs multiple functions automatically: it adheres to the trim breaker, surrounds the wrapper and liner edges, and cures to form the hermetic seal. This self-service capability reduces the need for additional sealing components or operations
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 between the inner liner, outer wrapper, and trim breaker, enabling effective thermal insulation and vacuum generation, even with dissimilar materials, by using a thermally elastic encapsulation material that accommodates thermal expansion and movement.
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
Implementation Method 2
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
Implementation Method 3
A thermally elastic encapsulation material that accommodates thermal expansion and movement
Data Source
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.