Method of controlling foaming of cabinet insulation

The method of controlling the forming of a foamed-in-place insulation in a cabinet structure having an inner liner and an outer shell, said liner having an outer surface and said shell having an inner surface in outwardly spaced confronting relationship to said outer surface to define an insulating space therebetween having a front opening, said method comprising the steps of:

• securing a first deflectible sheet to one of said surfaces adjacent said opening, said sheet having a stiffness preselected to cause the sheet to project away from said one surface;
• securing a second deflectible sheet to said other surface at said opening;
• inserting said liner into said shell to define said insulation space therebetween;
• and
• introducing expandable foam insulating material into said insulation space to deflect said sheets toward said front opening and cause the projecting portion of said first sheet to engage the other of said surfaces with said sheet extending between said liner and shell to define an outer boundary of the foamed insulation across said opening, said second sheet being deflected by the upwardly expanding foam insulation to define a portion of the upper boundary of the foamed insulation across said opening.

The method of assembling a foamed-in-place, insulated cabinet structure, comprising the steps of:

• forming an outer cabinet member having a peripheral portion;
• forming an inner liner having a peripheral portion;
• securing a first portion of a strip flexible sealing material to said liner about its peripheral portion, the remainder of said strip projecting away from said liner, said material permitting air flow therethrough and preventing foam flow therethrough;
• positioning said liner within said cabinet member in spaced relationship thereto so as to define an insulation space therebetween, said cabinet flange portion and said liner peripheral portion being in spaced adjacent relationship with said strip extending to adjacent said outer cabinet member peripheral portion;
• positioning a breaker strip to extend between said peripheral portions outwardly of said strip;
• and
• causing expansion of foam insulation in said insulation space such that as said foam expands toward said peripheral cabinet and liner portions to substantially fill said insulation space said remainder of the strip is deflected to a position extending across the insulation space between said flange and said peripheral liner portion thereby sealing said space against the escape of said foam insulation therefrom while permitting air to escape from said space during the expansion of the foam.

The method of assembling a foamed-in-place, insulated cabinet structure, comprising the steps of:

• forming an outer cabinet member having an inwardly extending peripheral flange portion;
• forming an inner liner having a peripheral portion;
• securing a first strip of flexible sealing material to one of said cabinet member and liner about its peripheral portion;
• securing a second strip of flexible material to the other of said cabinet member and liner about its peripheral portion;
• positioning said liner within said cabinet member in space relationship so as to define an insulation space therebetween said cabinet flange portion and said line peripheral portion being in spaced adjacent relationship;
• and
• causing expansion of foam insulation in said insulation space such that as said foam expands toward said peripheral cabinet and liner portions said first strip is deflected to a position extending across the insulation space between said flange and said peripheral liner portion thereby sealing said space from the escape of said foam insulation, said second strip being deflected by the foam insulation to cooperate with said first named strip to seal said space against the escape of said foam insulation therefrom.