Multi-layer encapsulation system for joint sealing of vacuum insulated cabinets

An appliance comprising:

• 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;
• a composite encapsulation system that seals an insulating cavity defined between the outer wrapper and the inner liner, the composite encapsulation system including 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.

A method for forming an insulating cabinet for an appliance, the method comprising steps of:

• delivering a base adhesive in an uncured state into a channel of a trim breaker;
• disposing a wrapper edge of an outer wrapper into the channel so that the base adhesive in the uncured state surrounds both sides of the wrapper edge within the channel;
• disposing a liner edge of an inner liner into the channel so that the base adhesive in the uncured state surrounds both sides of the liner edge within the channel;
• curing the base adhesive;
• disposing an outer adhesive over the base adhesive, wherein the outer adhesive covers the base adhesive and engages the outer wrapper and inner liner at the trim breaker;
• and
• curing the outer adhesive such that the base adhesive and outer adhesive cooperate to define structural and sealing components of a composite encapsulation system.

A method for forming an insulating cabinet for an appliance, the method comprising steps of:

• delivering a base adhesive in an uncured state into a wrapper channel and a liner channel of a trim breaker;
• disposing a wrapper edge of an outer wrapper into the wrapper channel so that the base adhesive in the uncured state surrounds both sides of the wrapper edge within the wrapper channel;
• disposing a liner edge of an inner liner into the liner channel so that the base adhesive in the uncured state surrounds both sides of the liner edge within the liner channel;
• curing the base adhesive to define a structural adhesive component;
• disposing a medial buffer layer onto at least a portion of the cured base adhesive;
• disposing an outer adhesive over the medial buffer layer, wherein the outer adhesive extends from an outer edge of the trim breaker to an outside surface of the outer wrapper and also extends from an inner edge of the trim breaker to an inside surface of the inner liner;
• curing the outer adhesive to define a composite encapsulation system having the structural adhesive component and the outer adhesive in a cured state that defines a sealing component, wherein the structural adhesive component and the sealing component are separated by the medial buffer layer, wherein the base adhesive engages a lower surface of the medial buffer layer and the outer adhesive binds to an upper surface of the medial buffer layer.