Refrigerator

Abstract

The present application provides a refrigerator which ensures the strength of a cabinet and reduces the amount of foamed thermal insulation material filled. The refrigerator of the present application has a cabinet which forms a storage chamber with an open front, is filled with foamed thermal insulation material in the area between an inner cabinet and an outer cabinet, and has a larger upper and lower dimension than a left and right dimension. The left and / or right side of the cabinet is configured to have a front end thermal insulation material which is continuously filled with the foamed thermal insulation material in the front end in the upper and lower direction, to have an area with a smaller thickness in which the foamed thermal insulation material can flow compared to the surrounding area, and to have other thermal insulation material with a higher thermal insulation performance than the foamed thermal insulation material.

Description

Technical Field

[0001] This invention relates to a refrigerator. Background Technology

[0002] To meet the demands for space saving and large capacity, refrigerator technologies exist that increase internal volume by thinning the refrigerator walls. The energy-saving performance of a refrigerator is primarily achieved through the combined use of vacuum insulation and foam insulation materials. Therefore, in recent years, refrigerators have been proposed that improve the coverage and thickness of vacuum insulation materials with superior insulation performance while reducing the thickness of foam insulation materials. For example, Patent Document 1 discloses a refrigerator where the area of ​​the back insulation wall without foam insulation material is larger than the area of ​​the side insulation walls without foam insulation material (claim 1, etc.).

[0003] Existing technical documents

[0004] Patent documents

[0005] Patent Document 1: Japanese Patent No. 6023941 Summary of the Invention

[0006] The problem that the invention aims to solve

[0007] However, existing technologies for refrigerators, such as Patent Document 1, concerning reducing the amount of foamed insulation material only consider the back of the insulation box, not the sides, top, or bottom. Therefore, the inventors focused on the following: if the specific foamed insulation material has a relatively small impact on the strength of the refrigerator, then even in the aforementioned parts of the box, the amount of foamed insulation material can be reduced.

[0008] Solution for solving the problem

[0009] In view of the above-mentioned issues, the refrigerator of the present invention includes a cabinet having a storage compartment with a front opening, a foamed insulation material being foamed and filled in the area between the inner and outer cabinets, and the vertical dimension of the cabinet being larger than the horizontal dimension. The left and / or right sides of the cabinet are configured such that a front insulation material is continuously foamed and filled with the foamed insulation material in the vertical direction at the front end, and a region with a smaller thickness of foamed insulation material that can flow compared to the surrounding area is provided, and other insulation materials with higher insulation performance than the foamed insulation material are provided. Attached Figure Description

[0010] Figure 1 This is the front view showing the exterior of the refrigerator.

[0011] Figure 2 This is a three-dimensional view showing the structure of the insulated compartment in a refrigerator.

[0012] Figure 3It is a diagram showing the required filling locations for strength based on the amount of foamed insulation material filled, analyzed by process.

[0013] Figure 4 This is a rear-view 3D view of the refrigerator's interior.

[0014] Figure 5 This is a top view of the refrigerator.

[0015] Figure 6 yes Figure 5 AA section view.

[0016] Figure 7 yes Figure 5 BB sectional view.

[0017] Figure 8 yes Figure 5 CC section view.

[0018] Figure 9 yes Figure 5 DD section view.

[0019] Figure 10 This is a picture showing the top of the refrigerator compartment viewed from the front.

[0020] Figure 11 This is a partial sectional perspective view showing the area near the internal light at the top of the refrigerator compartment.

[0021] Figure 12 This is a three-dimensional view of the top of the refrigerator compartment, excluding the outer box, inner box, and vacuum insulation material, viewed from above.

[0022] Figure 13 This is a partial cross-sectional view of the top of the refrigerator compartment viewed from the front.

[0023] Figure 14 This is a top-down view of the top of the refrigerator compartment, showing the vacuum insulation material, the internal lights, and the wiring for the internal lights.

[0024] Figure 15 This is a perspective view showing the structure of the insulated partition that separates the lower freezer compartment from the vegetable compartment.

[0025] Figure 16 This is a top view of the insulation partition.

[0026] Figure 17 yes Figure 16 AA section view.

[0027] Figure 18 yes Figure 16 BB sectional view.

[0028] Figure 19 yes Figure 16 CC section view.

[0029] Figure 20 yes Figure 16 DD section view.

[0030] Figure 21 This is a three-dimensional view of the insulation partition from below.

[0031] Figure 22 This is a top view taken from above, excluding the upper shell, within the insulated partition section.

[0032] Figure 23 yes Figure 22 A magnified 3D view of the dashed part F.

[0033] Figure 24 This is a diagram showing a simplified structure of the top in Embodiment 2.

[0034] Figure 25 This is a simplified cross-sectional view of the thermal insulation structure.

[0035] Figure 26 This is a schematic diagram illustrating a situation where the strength of the shelf is ensured. Detailed Implementation

[0036] Hereinafter, embodiments of the present invention will be described with reference to the accompanying drawings.

[0037] Example 1

[0038] The refrigerator of Embodiment 1 will be described in detail with reference to the accompanying drawings. Figure 1 This is a front view showing the exterior of refrigerator 1. Furthermore, in each drawing, directions based on the user's perspective are defined as front, back, left, right, up, and down.

[0039] <Basic Structure of a Refrigerator>

[0040] like Figure 1As shown, the refrigerator 1 of this embodiment has storage compartments arranged from top to bottom in the following order: refrigerator compartment 2, ice-making compartment 3 arranged side by side, upper freezer compartment 4, lower freezer compartment 5, and vegetable compartment 6. The refrigerator 1 is equipped with doors for opening and closing each storage compartment. These doors are rotating refrigerator compartment doors 2a and 2b, which are divided into left and right sides to open and close the opening of refrigerator compartment 2; and pull-out ice-making compartment door 3a, upper freezer compartment door 4a, lower freezer compartment door 5a, and vegetable compartment door 6a, which respectively open and close the openings of ice-making compartment 3, upper freezer compartment 4, lower freezer compartment 5, and vegetable compartment 6. Furthermore, this embodiment uses a refrigerator with six doors as an example, but is not limited to a six-door refrigerator. Each pull-out door is equipped with a storage container and door side rails extending forward and backward, for example, allowing sliding along the rails on the inner side of the refrigerator 1.

[0041] Refrigeration compartment 2 is a refrigerated storage compartment with an average temperature of approximately 4°C, maintaining a refrigerated temperature range. Ice compartment 3, upper freezer compartment 4, and lower freezer compartment 5 are frozen storage compartments with an average temperature of approximately -18°C, maintaining a frozen temperature range. Vegetable compartment 6 is a refrigerated storage compartment with an average temperature of approximately 6°C, maintaining a refrigerated temperature range, and using indirect cooling to inhibit food drying.

[0042] The front ends of the shelf ribs 13 located on both sides of the refrigerator compartment 2 are positioned away from the front end of the refrigerator 1 and extend rearward from there. Shelves are placed on the shelf ribs 13, and food can be placed on these shelves. In this embodiment, multiple shelves are arranged vertically.

[0043] A condenser is installed at the rear of the lower freezer compartment 5 to cool each storage compartment. Although not shown in the diagram, the condenser, compressor, condenser, and capillary tube are connected to form a refrigeration cycle. Furthermore, a blower is installed above the condenser to circulate the cooled air, and an outlet for discharging cold air into the storage compartments is formed downstream of the blower. Multiple condensers may be installed, and their placement is not limited to the rear of the lower freezer compartment 5; they may also be installed at the rear of the refrigerator compartment 2.

[0044] The guide rail connects to the side rail of the pull-out door, supporting the door. A container for holding food is installed on the door or the side rail, moving with the door.

[0045] <Basic Structure of Insulation Box>

[0046] Figure 2 This is a perspective view showing the structure of the insulated cabinet in refrigerator 1 of this embodiment. Figure 2 As shown, the insulation enclosure consists of a top surface, bottom surface, two sides, and a back surface, and is box-shaped with an opening at the front. Furthermore, the insulation enclosure has a metal outer casing 7 ( Figure 2(Not shown in the image) and an inner box 8 made of synthetic resin, the space inside the insulated box formed by the outer box 7 and the inner box 8 is filled with a foamed insulation material 9 such as rigid polyurethane foam in a so-called on-site foaming manner to insulate the storage room from the outside.

[0047] The outer casing 7 is box-shaped, consisting of a top panel formed by bending thin steel sheets into a door shape, left and right side panels, a back panel composed of different components, and a bottom panel composed of different components. The inner casing 8, on the other hand, is box-shaped by molding synthetic resin sheets. The top panel and the left and right side panels can also be separated.

[0048] Furthermore, the refrigerator compartment 2 is separated from the ice-making compartment 3 and the upper freezer compartment 4 by an insulated partition 10 arranged as a generally horizontal surface. The lower freezer compartment 5 and the vegetable compartment 6 are separated from each other by an insulated partition 11 arranged as a generally horizontal surface. These insulated partitions are provided to divide the storage compartments into different temperature zones, preventing the refrigerator compartment from becoming too cold due to the cold air from the freezer compartment.

[0049] Furthermore, between the outer casing 7 and the inner casing 8, in addition to the foamed insulation material 9, a vacuum insulation material 12 with a lower thermal conductivity than the foamed insulation material 9 is also installed. Figure 2 (Not shown in the image), the insulation performance can be improved without reducing the food storage volume. Here, in order to ensure air barrier properties, the vacuum insulation material 12 is constructed by wrapping a core material such as glass wool with an outer material formed of a metal layer such as aluminum. The vacuum insulation material 12 is attached to the inner wall surface of the outer casing 7, namely the inner wall surface of the top panel, side panel, back panel, and bottom panel, respectively, using adhesives such as double-sided tape or hot melt adhesive, on part or the entire surface of the vacuum insulation material 12.

[0050] The on-site foamed insulation material 9 has a lower thermal conductivity than the vacuum insulation material 12, but it can use its adhesive strength to integrate the inner box 8 and the outer box 7, thus improving the strength of the insulation box. The injection method for on-site foaming of the polyurethane insulation material 9 is as follows: With the refrigerator 1 lying face down with its back facing vertically upwards, the material is injected into the space between the inner box 8 and the outer box 7 through, for example, four injection ports located on the back of the outer box 7. The injected polyurethane insulation material drips onto the side near the front end of the insulation box, where foaming begins, moving upwards along the side and spreading towards the back, thereby filling and hardening.

[0051] In other words, the space between the vacuum insulation material 12 and the inner box 8 is essentially filled with foamed insulation material 9 and foamed, and then fixedly installed with the inner box 8 to ensure the strength of the refrigerator. However, in this embodiment, the part with less impact on strength is the part that is not filled or is partially filled with foamed insulation material 9 (locally without polyurethane). Specifically, in this embodiment, the polyurethane flow thickness (the gap between the inner box 8 and the vacuum insulation material 12) of the entire area or circumference of the partially unfilled polyurethane area is, for example, less than 6 mm. Thus, the unfilled polyurethane (void) is not due to unexpected dimensional deviations of the vacuum insulation material 12, but rather allows for the creation of areas with little or no polyurethane filling, resulting in a reduction in the overall amount of polyurethane insulation material injected into the refrigerator 1. The connection between the thicker parts of the foamed insulation material 9 (e.g., parts with a flow thickness of 8 mm or more) and the thinner parts of the unfilled or partially filled polyurethane areas is such that, for example, the inner box 8 approaches the outer box 7 in a conical shape, with the flow thickness changing continuously. Thus, stress concentration caused by loads resulting from abrupt changes in rigidity can be avoided. Furthermore, the pressure loss in the air duct can be reduced at the location of the cold air flow. On the other hand, if the inner box 8 is connected in a stepped manner, for example, the internal volume of the storage compartment can be maximized, ensuring the flow thickness and thus reducing the risk of the connection not being filled with polyurethane.

[0052] Furthermore, the material embedded between the outer casing 7 and the inner casing 8 along with the foamed insulation material 9 is not limited to the vacuum insulation material 12; any material with a lower thermal conductivity λ compared to the foamed insulation material 9 may be used. For example, the vacuum insulation material 12 described in each embodiment may be replaced with... Figure 25 The insulation structure 30 shown is formed by overlapping a first plate 31a, made of stainless steel, PCM steel, glass, or the like, with a thickness of 0.5 to 2.0 mm, and a second plate 31b, creating an internal space 32 between them. It has a joint 33 that joins the outer peripheries of the first plate 31a and the second plate 31b using welding, bonding, or the like. Multiple spherical spacers 34, made of glass, ceramic, or the like, are arranged in the internal space 32, and the height of the internal space 32 is set to approximately 2 to 5 mm. A vacuum is created in the internal space 32 through an exhaust port 35 located on either the first plate 31a or the second plate 31b, and the space is then sealed with a cover 36. By creating a vacuum atmosphere in the internal space 32 of the insulation structure 30, the thermal conductivity λ can be made smaller than that of the foamed insulation material 9.

[0053] <Overview of Partial Polyurethane-Free Treatments>

[0054] Figure 3This diagram illustrates the required filling locations for strength through analysis. Foamed insulation material 9 fills the inner box 8 and outer box 7, or the insulation space formed by vacuum insulation material 12, etc., and hardens to ensure the refrigerator's strength, but it does not contribute equally to all spaces as a structural element. Figure 3 The results show the determination of the rigid polyurethane portion required for the refrigerator using a density-based optimization method. As this is a prerequisite for the refrigerator's establishment, conditions are set for applying loads to the shelves mounted on the shelf ribs 13 and the guide rails 21 that support the pull-out storage compartment containers.

[0055] Based on the result of filling the entire insulation space, the most efficient polyurethane injection spaces are shown when 10%, 30%, and 70% polyurethane are injected from left to right. Spaces requiring less fill are primarily the front end (opening) and the front and rear center of the side sections, indicating a significant contribution to rigidity in these areas. As the fill increases, the filled portion extends rearward from near the front opening and connects with the side center; however, if the fill is small, it does not extend to the rear, bottom, top, or rear sides of the side, indicating a smaller contribution to the rigidity of the polyurethane within these insulation spaces. It can be seen that even in the side center, the contribution above the uppermost shelf rib 13 and below the lowermost guide rail 21 is relatively small.

[0056] The front side is important because the refrigerator 1 is generally rectangular in shape and has an opening on its front surface. Therefore, it is necessary to ensure the rigidity of the edges of the surface forming the opening, especially the long sides. In contrast, the short sides (the front ends of the top and bottom surfaces) are less necessary. Furthermore, when the hinge portion 22 supporting the rotating door is provided, polyurethane needs to be filled around the hinge portion 22 to improve rigidity. Therefore, it is preferable that the front side is filled with polyurethane throughout its entire upper and lower areas.

[0057] The location of the shelf ribs 13 and guide rails 21, which are continuously located on the front and rear central sides of the side, particularly along the long, vertically extending side of the front end of the insulated box, contributes significantly to the strength of the polyurethane. This is important because the rigidity of the shelf ribs 13 and guide rails 21, which bear the load of the shelf and the food placed in the container, is necessary to support the food load. This allows for a reduction in the amount of polyurethane used in areas with other shelf supports. For example, if the shelf support is located at a certain position on the back, it can be replaced by filling the back shelf support area with a large amount of polyurethane instead of the side support.

[0058] Based on this analysis, the flow thickness of the foamed insulation material 9 in the front end of the insulation box (refrigerator 1), the shelf rib 13, and the guide rail 21 of the insulation box in this embodiment is increased. Specifically, a foamed insulation material 9 (front end insulation material 91) is provided at the front end of the side by increasing the flow thickness throughout the entire upper and lower area of ​​the refrigerator 1. Figure 3 In the diagram, the symbol 91' is used to indicate the location of the front-end insulation material. Therefore, the front-end side, which is important for strength, is filled with foamed insulation material 9, and the filling of the rear-end side with foamed insulation material 9 can be omitted. Furthermore, on the side, if the area from the front end to the rear at a predetermined distance is called the front-end side (opening side), and the area from this point to the rear is called the rear-end side, then the overall flow thickness on the front-end side is larger than that on the rear-end side. The boundary between the front and rear ends may differ vertically on the side, but for example, it may be the rear end of the front-end insulation material 91 or behind it.

[0059] Specifically, such as in Figure 2 As illustrated on the left side, in the refrigerator 1 of this embodiment, in a portion 81 above the uppermost shelf rib 13 and a portion 84 below the lowermost guide rail 21 on the side, the flow thickness is reduced and the foamed insulation material 9 is unfilled or poorly filled. Furthermore, in the region 82 extending vertically from the uppermost shelf rib 13 to the lowermost guide rail 21 and from the front insulation material 91 to the front-rear region of the shelf rib 13 or guide rail 21, and in the region 83 sandwiched vertically by the shelf rib 13 or guide rail 21, the flow thickness is also reduced and the foamed insulation material 9 is unfilled or poorly filled. Additionally, in Figure 2 The front end of region 83 is depicted at a position further back than the front and rear center of shelf rib 13 or guide rail 21, but the front end of region 83 may also extend to the front end of shelf rib 13 or guide rail 21.

[0060] For example, as a boundary between the front and rear sides, in the case of a refrigerator 1 with shelf ribs 13 / guide rails 21 as in this embodiment, the following can be considered.

[0061] First, regarding the vertical position of the shelf rib 13 / guide rail 21, it can be set to a position slightly forward of the front end of the shelf rib 13 / guide rail 21, at the center of the front-to-back dimensions of the shelf rib 13 / guide rail 21. Setting it slightly forward of the front end of the shelf rib 13 / guide rail 21 reduces the flow thickness in areas with less impact on strength (the front side, shelf rib 13, and areas other than guide rail 21), which is preferable. However, in a field foaming method where polyurethane raw material is injected from the injection port on the back of the refrigerator 1, the foaming path from the front side to the shelf rib 13 / guide rail 21 is easily blocked, and voids are easily created in the shelf rib 13 / guide rail 21. Therefore, in this embodiment, the flow thickness of region 82 is increased to the same extent as the front insulation material.

[0062] On the other hand, if the center of the front and rear dimensions of the shelf rib 13 / guide rail 21 is set as the boundary, the amount of polyurethane filling cannot be reduced at positions further forward. However, even in the shelf rib 13 / guide rail 21, which has a greater impact on strength, it is relatively easy to fill with foamed insulation material 9. Therefore, for example, the flow thickness of region 83 can also be reduced.

[0063] Secondly, the vertical range above the uppermost shelf rib 13 and below the lowermost guide rail 21 can be set to the rear end of the aforementioned front insulation material or a position further back. In this embodiment, a region 81 is provided above the uppermost shelf rib 13, extending from the rear end of the front insulation material 91 to approximately the rear end of the side surface, reducing the flow thickness. The rear end position of region 81 is not particularly limited. Furthermore, a rectangular region 84 is provided below the lowermost guide rail 21 and near the rear end of the front insulation material, reducing the flow thickness. The rear end of region 84 can also be... Figure 2 The location shown is towards the back.

[0064] Furthermore, regions 81 to 84 are preferably able to overlap with the vacuum insulation material 12 in the side view, and are located inside the edge of the vacuum insulation material 12.

[0065] Next, as the boundary between the front and rear sides, in the case of a refrigerator without shelf ribs 13 and guide rails 21, it can be set to, for example, a position of 1 / 3 or 1 / 2 of the front-to-back dimension from the front to the back of the inner box.

[0066] Thus, on the side of the refrigerator 1, the ratio of the area filled by increasing the flow thickness relative to the sum of the area filled by increasing the flow thickness of the foamed insulation material 9 (e.g., the area where the front insulation material 91 is provided) and the area that is not filled or is less filled due to decreasing the flow thickness is higher on the front side of the side than on the rear side of the side. Figure 2 In the left side, the flow thickness can be reduced in regions 81-84, and increased in the remaining regions. In this embodiment, the flow thickness is reduced in regions 81 and 84, and increased in the remaining regions. The right side can be constructed in the same way as the left side.

[0067] In this way, in addition to the front insulation material 91, the side of the refrigerator 1 is also filled with foamed insulation material 9 (food support insulation material) by increasing the polyurethane flow thickness in the projection surfaces of the shelf ribs 13 and guide rails 21. If the projection surfaces of the shelf ribs 13 and guide rails 21 are filled with at least foamed insulation material 9, it is possible to ensure the coverage of important positions for food load.

[0068] To foam the food support insulation material on-site, for example, the flow thickness of the polyurethane can be increased across the entire area from the uppermost shelf rib 13 to the lowermost guide rail 21 to fill the foamed insulation material 9. Alternatively, as in area 83, the flow thickness of the area sandwiched between the shelf rib 13 and the guide rail 21 can be reduced, resulting in little or no foamed insulation material being filled. In this embodiment, the former method is used. In the latter case, the food support insulation material becomes so-called "insect-eaten" in a state.

[0069] In the front-rear direction of the side of the refrigerator 1, between the aforementioned front-end insulation material and the food support insulation material, foamed insulation material 9 can be filled in a way that connects them, or the flow thickness can be reduced (e.g., reducing part or all of the flow thickness of region 82) to leave it unfilled or with minimal filling. If foamed insulation material 9 is filled between the front-end insulation material 91 and the food support insulation material (e.g., region 82), it is easy to fill the food support insulation material in the case of on-site foaming. If foamed insulation material 9 is left unfilled or filled with minimal filling, the impact on the strength (rigidity) of the refrigerator 1 can be suppressed, and the amount of polyurethane can be reduced. If the flow thickness of a portion of region 82 is reduced, multiple regions with smaller flow thicknesses are provided vertically and horizontally, ensuring that regions with larger flow thicknesses are also ensured. Therefore, the foamed insulation material 9 can flow easily in these regions, making it easier to fill towards the rear. In other words, it is preferable to suppress the formation of voids in the areas that should be food support insulation materials.

[0070] Furthermore, if other components with higher rigidity than the hardened foamed insulation material 9 are installed in the area to be the food support insulation material for reinforcement, the flow thickness of the entire area between the front insulation material and the food support insulation material, such as area 82, can be further increased, and the flow thickness of the entire area overlapping with the shelf rib 13 or the rail 21 can be reduced, since the necessity of foam filling in the area to be the food support insulation material is eliminated or reduced. The shelf rib 13 and the rail 21 are important only when considering the support of the food load. The front insulation material is important for the strength of the structure of the inner and outer boxes, allowing the food load to be supported by reinforcements instead of the foamed insulation material 9. Figure 26 This is a schematic diagram showing a case where a reinforcing member 23, consisting of a resin component or a metal component, is provided between the inner box 8 and the vacuum insulation material 12 to ensure the strength of the shelf.

[0071] As mentioned above, the front end contributes more to the strength, therefore the flow thickness is greater on the front side than on the rear side. This will be explained in detail below regarding the top and bottom surfaces. In this embodiment, since no shelf ribs or guide rails are provided on the top and bottom surfaces, the boundary can be, for example, 1 / 3 or 1 / 2 of the front-to-rear dimension of the refrigerator 1 from the front end. The top and / or bottom surfaces can also be filled with foamed insulation material 9 at the front end, in which case it can be continuous with the front insulation material 91 on the side. In this embodiment, foamed insulation material 9 is also filled at the front end of both the top and bottom surfaces, resulting in a larger flow thickness across the entire front area of ​​the insulation box, i.e., the rectangular area.

[0072] One method to reduce the flow thickness of the polyurethane can be, for example, by recessing the inner box 8 towards the outer box 7. This expands the internal volume of the storage compartment. Regarding the insulation performance of the refrigerator 1, since the contribution of the vacuum insulation material 12 is much greater than that of the foamed insulation material 9, from the viewpoint of expanding the internal volume and reducing the amount of polyurethane, it is preferable to reduce the flow thickness in the area where the flow thickness is reduced to the point where the foamed insulation material 9 is not filled. That is, when reducing the flow thickness in the area where the vacuum insulation material 12 is provided (the distance between the outer box 7 and the inner box 8 where there is no structure such as the vacuum insulation material 12), when the vacuum insulation material 12 is installed in the inner box 8, the distance between the vacuum insulation material 12 (as the flow thickness) and the outer box 7 can be, for example, 6 mm or less, preferably 3 mm or less. Furthermore, when the vacuum insulation material 12 is installed in the outer box 7, the distance between the vacuum insulation material 12 and the inner box 8 can remain the same. On the other hand, in areas where the flow thickness is increased, the distance between the outer casing 7 and the inner casing 8, which constitutes the flow thickness, where there are no structures, can be, for example, 8 mm or more, 10 mm or more, 12 mm or more, or 15 mm or more. Furthermore, the flow thickness can also be set to be approximately the same as that of the front-end insulation material 91.

[0073] Furthermore, from the viewpoint of reducing polyurethane weight, the flow thickness can also be reduced by arranging other components between the inner box 8 and the outer box 7. Also, for example, when unfilled or poorly filled areas are shaped into certain patterns, it is not necessarily necessary to reduce the flow thickness of the pattern d content; the flow thickness can be reduced only along the entire edge of the pattern (i.e., the closed curve). In this case, the effect of internal volume expansion is reduced, but the amount of polyurethane is reduced.

[0074] In addition, regarding the top, bottom, and back surfaces of refrigerator 1, the amount of foamed insulation material 9 is reduced to support and protect the vacuum insulation material 12. This will be explained below.

[0075] <Details on partial polyurethane-free treatment>

[0076] Next, the specific structure of each part of the insulated cabinet in refrigerator 1 of this embodiment will be described. Figure 4 This is a rear-view 3D view of the inner compartment 8 of refrigerator 1. Figure 5 This is a top view of refrigerator 1 (showing the vacuum insulation material in perspective). Furthermore, Figure 6 yes Figure 5 AA section view, Figure 7 yes Figure 5 BB sectional view, Figure 8 yes Figure 5 CC section view, Figure 9 yes Figure 5 DD section view.

[0077] "top"

[0078] First, the construction of the top surface (top) of the insulation box will be described. For example... Figure 6 As shown, the front and rear sides of the top vacuum insulation material 12 are continuously filled with foamed insulation material 9. Here, between the lower surface of the vacuum insulation material 12 and the inner box 8, foamed insulation material 9 is only filled in the front area from the front end to the front area of ​​the inner box light 14 and the rear area from the rear end across the corner 20 (the inclined portion connecting the rear side to the top surface), and not in the central area (between the front and rear areas).

[0079] On the other hand, such as Figures 7-9 As shown, foamed insulation material 9 is also continuously filled to the left and right sides of the top vacuum insulation material 12. Here, as... Figure 7 As shown, in the area between the lower surface of the vacuum insulation material 12 and the inner box 8, foamed insulation material 9 is continuously filled from the left end to the right end in the front region, but as... Figure 8 and Figure 9 As shown, in the central area, the foamed insulation material 9 is not filled from the left end to the right end.

[0080] In this way, by partially eliminating polyurethane in the central region (region 85) below the vertical projection of the top vacuum insulation material 12, the amount of polyurethane insulation material injected can be reduced. Furthermore, even with partially polyurethane-free areas, foamed insulation material 9 is present around the top vacuum insulation material 12 (on the front, back, left, and right sides). Particularly in the front and rear regions, the foamed insulation material 9 supports the ends of the vacuum insulation material 12 from the lower surface to the sides in an enveloping manner, thus preventing the vacuum insulation material 12 from falling or causing thermal bridging. Simultaneously, by filling the area around the cabinet lamp 14 located near the polyurethane-free area with at least polyurethane insulation material, the fixing strength of the components associated with the cabinet lamp 14 can be ensured.

[0081] Furthermore, the same effect is achieved even when the left and right regions of the vacuum insulation material 12 are supported by the foamed insulation material 9 in an encapsulating manner, so the encapsulation is not limited to the front and rear regions.

[0082] As described in this embodiment, the top partial polyurethane-free area (area 85) is located inside the projection plane of the vacuum insulation material 12, for example, compared to the edge of the vacuum insulation material 12.

[0083] And, as Figure 9 As shown, the width of the vacuum insulation material 12 disposed on the top surface of the inner box 8 is smaller than the width of the top surface of the inner box 8. Therefore, in the region 9a between the left and right corners 8a of the top surface of the inner box 8 and the left and right ends of the vacuum insulation material 12, foamed insulation material 9 is filled between the outer box 7 and the inner box 8. The thickness of the foamed insulation material 9 in this region is equal to that of the vacuum insulation material 12. Since the thermal conductivity of the foamed insulation material 9 is greater than that of the vacuum insulation material 12, the insulation performance of this part is relatively small. If the insulation performance is insufficient, the outer box 7 will be cooled by the inside of the refrigerator, and condensation will occur on the outer box 7 due to the temperature difference between the outside air and the refrigerator, which is not recommended. In the refrigerator of this embodiment, the heat from the hot air pipe (not shown) disposed between the outer box 7 and the foamed insulation material 9 is used to prevent the outer box 7 from being cooled, thereby reducing the temperature difference between the outer box 7 and the outside air and preventing condensation.

[0084] In this way, the top surface of the inner box 8 (under the vertical projection of the vacuum insulation material 12 and region 9a) has a roughly the same planar shape, so that the internal volume can be increased in addition to the projection surface of the vacuum insulation material 12.

[0085] Opening section

[0086] Next, regarding the construction of the opening of the insulation box, as described above, the back of the refrigerator 1 is placed facing upwards, and polyurethane insulation material is injected from, for example, four injection ports provided on the back towards the front of the refrigerator 1 facing vertically downwards. In this embodiment, the flow thickness is increased not only across the entire upper and lower areas of the left and right sides corresponding to the long side, but also across the entire left and right areas of the top and bottom sides corresponding to the short side at the front (opening). Therefore, the foamed insulation material 9 can be continuously filled throughout the entire circumference of the opening of the refrigerator 1 (insulation box). This allows for the filling of the front insulation material.

[0087] Shelf Ribs

[0088] Next, use Figure 8 and Figure 9The structure of the portion forming the shelf rib 13 in the insulated cabinet will be described. On the side of the refrigerator 1, above the uppermost shelf rib 13, a recessed region (region 81) is formed where the inner box 8 slopes downwards towards the outer box 7, resulting in a smaller flow thickness. The recessed region (region 81) is not located at the front end of the side (see reference). Figure 7 ).

[0089] Polyurethane insulation material injected from the injection port on the back of refrigerator 1 is foamed on-site with the back of refrigerator 1 facing vertically upwards, as described above. Next, for example, the polyurethane insulation material foaming begins in the area forming the front insulation material and fills the area where the flow thickness increases. Therefore, within the inner box 8, including the area from the uppermost shelf rib 13 to the lowermost guide rail, the foamed insulation material 9 is filled upwards towards the back of refrigerator 1. In this way, food-supporting insulation material is continuously filled from the area of ​​the front insulation material.

[0090] On the other hand, the shelf ribs 13 that do not contribute to the support of the shelf ribs 13 and are located closer to the top shelf ribs 13 are not included in the support of the shelf ribs 13. Figure 8 The flow thickness on the side at the upper part (the upper part when using refrigerator 1) is reduced. In this embodiment, since the flow thickness is reduced to the point that the polyurethane cannot flow, the polyurethane insulation material does not move upward from the front end of refrigerator 1 at all.

[0091] <Top Plate>

[0092] Figure 10 This is a picture showing the top of refrigerator compartment 2 from the front. Figure 11 This is a partial cross-sectional perspective view showing the area near the internal light 14 at the top of the refrigerator compartment 2. The internal light 14 is covered by a light-transmitting cover. The material of the cover is not particularly limited, but a transparent synthetic resin is preferred.

[0093] On the top front side, because the internal light 14 is installed in the inner box 8, so as Figure 11 As shown, foamed insulation material 9 is filled between the inner box 8 and the vacuum insulation material 12 to improve the supporting strength of the inner light 14. On the other hand, the gap between the vacuum insulation material 12 and the inner box 8 is small (e.g., less than 1 mm) on the rear side of the top, and the inner box 8 is in a higher position, thus increasing the food storage space of the top shelf. Since the vacuum insulation material 12 does not contact the inner box 8, it serves as a cushioning material when users bump cans or other items against the top; even a small gap is preferable.

[0094] Thus, in areas where the gap between the vacuum insulation material 12 and the inner box 8 is small, the foamed insulation material 9 is not filled, and therefore, the inner box 8 is not fixedly installed relative to the outer box 7, with the vacuum insulation material 12 connected to the inner box 8 via the foamed insulation material 9. As a result, the inner box 8 sags due to its own weight, which is not aesthetically pleasing. Therefore, in this embodiment, polyurethane insulation material is injected and foamed with a synthetic resin top plate 16 installed below the inner box 8 without polyurethane portions, and the top plate 16 forms part of the top surface of the cold storage compartment 2.

[0095] <Roof Slab Support Structure>

[0096] The top plate 16 has an inclined surface 16a extending downward from the front side. A threaded fitting 17 is fastened from the outside of the inner casing 8 relative to this inclined surface 16a, preventing it from falling off. Therefore, the user cannot visually confirm the presence of the threaded fitting 17. Furthermore, since the head of the threaded fitting 17 is ultimately covered by the foamed insulation material 9, not only is loosening of the threaded fitting 17 suppressed, but also prevents the user from removing the threaded fitting 17 or damaging it by contact with the vacuum insulation material 12.

[0097] Furthermore, by making the front side of the top plate 16 an inclined surface 16a, the cold air expelled from the rear of the refrigerator compartment 2 is guided downwards at an angle, making it easier to cool the food inside the door shelf. Moreover, compared to a non-inclined step, it also has the advantages of making it easier to remove and place food, and the polyurethane insulation material flows more easily.

[0098] Figure 12 This is a perspective view of the top of the refrigerator compartment 2, excluding the outer box 7, inner box 8, and vacuum insulation material 12, viewed from above. Figure 13 This is a partial cross-sectional view of the top of refrigerator compartment 2 as seen from the front. (Example) Figure 12 As shown, a claw portion 16b is formed on the rear side of the top plate 16 and in the center in the left-right direction, which locks against the inner box 8. The claw portion 16b is only formed as a portion of the left-right width relative to the top plate 16, which has the same left-right width as the inner box 8, so the assembly workability of the top plate 16 is high.

[0099] The left and right ends of the top plate 16 are supported only by ribs (not shown) extending from the side wall of the inner box 8 in the front-rear direction, and are not restricted in the horizontal direction. Furthermore, the rear end of the top plate 16 is restricted only in the vertical direction by claws 16b. Therefore, it is possible to suppress thermal deformation of the top plate 16 due to changes in ambient temperature or deflection due to the foaming pressure of the foamed insulation material 9 applied through the inner box 8. In addition, if either the left or right ends or the front and rear ends of the top plate 16 are not restricted in the horizontal direction, the top plate 16 can be supported by other methods.

[0100] Furthermore, a first rib 16c extending in the front-rear direction from the left-right center and a second rib 16d extending in the left-right direction from the front-rear center are formed on the upper surface of the top plate 16, thereby improving the rigidity of the top plate 16. In addition, multiple first ribs 16c and second ribs 16d can be formed. Furthermore, multiple reinforcing sheets 16e extending in the left-right direction are formed at both ends of the top plate 16 and arranged in the front-rear direction, thus suppressing deformation of the top plate 16 due to the foaming pressure of the foamed insulation material 9 filled between the inner box 8 and the outer box 7 forming the left and right sides.

[0101] Here, the inner box 8 and the top plate 16 are not glued together, as shown. Figure 13 As shown, a gap is formed between the inner box 8 and the top plate 16, so that even if the inner box 8 sags to a certain extent, it will not exert a load on the top plate 16. Furthermore, the first rib 16c and the second rib 16d also serve to prevent the entire surface of the inner box from contacting the top plate 16 even if it sags. Moreover, since the top plate 16 in this embodiment is molded with less than 10% by mass of glass filler, warping during molding is minimal. Furthermore, the material of the top plate is not limited to synthetic resin; it can also be a structure installed after the polyurethane insulation material is injected and foamed.

[0102] <Top wiring>

[0103] Figure 14 This is a top view of the top of the refrigerator compartment 2, showing the vacuum insulation material 12, the internal light 14, and the wiring (wires 15) used for the internal light 14. (See diagram below.) Figure 14 As shown, the wire 15 leading from the light 14 inside the box passes through the side of the vacuum insulation material 12 to the rear, and then descends on the rear side to connect with the control board (not shown).

[0104] Here, as Figure 6 As shown, the area between the lower surface of the top vacuum insulation material 12 and the inner box 8, except for the front and rear regions, is not filled with foamed insulation material 9. If wires 15 are placed in the unfilled areas, there is a possibility that the inner box 8 may be pressed with marks from the wires 15 when the polyurethane insulation material is foamed and pressed from the inner box 8 side by a clamp, or that the wires 15 may damage the vacuum insulation material 12. Therefore, in this embodiment, wires 15 are placed in the areas filled with foamed insulation material 9. That is, the area where wiring is laid below the vertical projection of the vacuum insulation material 12 is only the front and rear regions where the foamed insulation material 9 is present, with wiring extending beyond the portion of the vacuum insulation material 12 where the foamed insulation material 9 is present.

[0105] If a pre-foamed foam or other clamping component is provided between the wire 15 and the inner box 8, or if a space is provided on the side of the inner box 8 and the side of the vacuum insulation material 12 to avoid the wire 15, then the wire 15 can be laid even in the part that is not filled with the foam insulation material 9.

[0106] <Insulated Part>

[0107] Next, the insulated partition 11 that separates the lower freezer compartment 5 from the vegetable compartment 6 will be described in detail. Figure 15 This is a perspective view showing the structure of the insulated partition 11 that separates the lower freezer compartment 5 (freezing temperature zone) from the vegetable compartment 6 (refrigeration temperature zone). Figure 15 As shown, the thermal insulation partition 11 is formed by combining the upper shell 111 and the lower shell 112. Furthermore, within the space enclosed by the upper shell 111 and the lower shell 112, the thermal insulation partition 11 includes, from top to bottom, vacuum insulation material 12 and a heater 113. Moreover, when the space between the outer casing 7 and the inner casing 8 is filled with foamed insulation material 9, polyurethane insulation material injected from the four injection ports located on the rear side of the thermal insulation housing flows into the interior of the thermal insulation partition 11 through polyurethane inlets 11a formed on the left and right front sides of the thermal insulation partition 11. The polyurethane insulation material flowing into the interior of the thermal insulation partition 11 spreads and fills the area around the vacuum insulation material 12, and is finally fixedly installed relative to the thermal insulation housing together with the upper shell 111 and the lower shell 112.

[0108] "The Shell"

[0109] The upper shell 111 faces the lower freezer compartment 5, but if Figure 15 As shown, because there are two upper surface recesses 111a on the left and right sides, the internal volume of the lower freezer compartment 5 can be increased. Furthermore, the lower surface recesses 112a of the lower shell 112 (see reference) Figure 21 ) and the bent portion 12a of the vacuum insulation material 12 located above it (see reference) Figure 18 In the form corresponding to the front side of the upper surface recess 111a, the bottom surface is shallower on the front side compared to the rear side. Furthermore, a bridging portion 111b with the same height as the perimeter of the upper surface recess 111a is formed in the portion sandwiched between the left and right upper surface recesses 111a.

[0110] Figure 16 This is a top view of the insulated partition 11 as seen from above (towards the lower freezer compartment 5). Figure 17 yes Figure 16 AA section view, Figure 18 yes Figure 16 BB sectional view, Figure 19 yes Figure 16 CC section view, Figure 20 yes Figure 16 DD section view.

[0111] like Figure 17 and Figure 18 As shown, a piece of vacuum insulation material 12 with a bent portion 12a is located below the upper shell 111. The front-to-back dimensions of the vacuum insulation material 12 are the same as or larger than the front-to-back dimensions of the upper surface recess 111a. The left end of the vacuum insulation material 12 is located at the same position as or further to the left of the left end of the left upper surface recess 111a, and the right end of the vacuum insulation material 12 is located at the same position as or further to the right of the right end of the right upper surface recess 111a. Here, for the portion below where the upper surface recess 111a is formed (refer to...) Figure 18 Regarding the bridging portion 111b, which is the part between the two upper surface recesses 111a, below (see reference) Figure 17 Compared to the previous type, the gap between the upper shell 111 and the vacuum insulation material 12 is smaller (e.g., less than 6 mm). Therefore, the polyurethane insulation material flowing into the interior of the insulation partition 11 from the polyurethane inlet 11a cannot flow into the space sandwiched between the portion with the upper surface recess 111a and the vacuum insulation material 12, but instead flows into the space sandwiched between the portion without the upper surface recess 111a and the vacuum insulation material 12. In other words, as... Figure 16 As shown by dotted line E, the flow path of the polyurethane insulation material flows through the gaps below the recesses 111a on each upper surface, eventually becoming a form that encounters the underside of the bridging portion 111b from the front and back.

[0112] In this way, near the center of the insulation partition 11, because foamed insulation material is filled all the way down below the bridging portion 111b of the upper shell 111, the deflection of the upper shell 111 is reduced, the rigidity of the insulation partition 11 is increased, and damage to the vacuum insulation material 12 is suppressed. Furthermore, the polyurethane insulation material flowing in from the polyurethane inlet 11a is branched into multiple directions by the upper surface recess 111a. Since the branched flow of polyurethane insulation material can be touched by any part (the final filling portion) within the insulation partition 11, there is a risk of voids being generated. However, by providing the bridging portion 111b, a flow of polyurethane insulation material into the front and rear ends below the bridging portion 111b can be formed. Because the polyurethane flowing from the front and rear ends below the bridging portion 111b collides, even if voids are generated, they can be stopped within the area of ​​the bridging portion 111b. Furthermore, vacuum insulation material 12 is present under the vertical projection of the bridging portion 111b. That is, even if voids are generated, the location of the voids can be stopped within the area of ​​the vacuum insulation material 12, thus minimizing the impact of voids on the insulation performance of the insulation partition wall. In addition, this embodiment has a structure in which the upper surface recesses 111a are arranged horizontally and the bridging portion 111b is formed in the front-back direction, but it can also be a structure in which the upper surface recesses 111a are arranged vertically and the bridging portion 111b is formed in the left-right direction. Moreover, in order to ensure the inflow of polyurethane, the height of the bridging portion 111b is formed to be at least higher than the lower surface of the upper surface recesses 111a, so it is not limited to this embodiment.

[0113] And, as Figure 17 and Figure 18 As shown, foamed insulation material 9 is filled on the front and rear sides of the vacuum insulation material 12, and as... Figure 19 and Figure 20 As shown, foamed insulation material 9 is also filled on the left and right sides of the vacuum insulation material 12. On the other hand, double-sided tape (not shown) is adhered to a portion of the lower surface of the vacuum insulation material 12, bonding it to the lower shell 112. Therefore, foamed insulation material 9 is essentially not filled between the vacuum insulation material 12 and the lower shell 112. However, as... Figure 20 As shown, below the front side of the bent portion 12a of the vacuum insulation material 12, in addition to the area of ​​the lower surface recess 112a formed on the front side of the lower shell 112, a large gap is generated between it and the lower shell 112, so the foamed insulation material 9 is filled.

[0114] Thus, in this embodiment, the upper and lower surfaces of the vacuum insulation material 12 within the insulation partition 11 are partially free of polyurethane. Therefore, as a whole, the refrigerator 1 has the advantage of reducing the amount of foamed insulation material 9 required. Furthermore, foamed insulation material 9 is filled in the front, back, left, and right sides of the vacuum insulation material 12, thus stably supporting the vacuum insulation material 12 within the insulation partition 11 and ensuring the strength of the insulation partition 11.

[0115] Lower Shell

[0116] Figure 21 This is a perspective view of the insulated partition 11 from below (side 6 of the vegetable compartment). (See image below.) Figure 21 As shown by the dashed and dotted lines, a heater 113 is located above the lower shell 112, and a vacuum insulation material 12 is located above the heater 113. Furthermore, although not shown, the refrigerator 1 of this embodiment can be configured to have a vegetable compartment cover on the upper surface of a container capable of being opened and closed, forming the vegetable compartment 6. This vegetable compartment cover suppresses the drying of vegetables inside the container by improving the container's airtightness and is supported by the vegetable compartment cover mounting portion 112b located on the lower shell 112 of the insulation partition 11.

[0117] The lower shell 112 has a vegetable compartment cover mounting portion 112b on its front side and lower surface recesses 112a arranged in the left-right direction of the vegetable compartment cover mounting portion 112b. The lower surface recesses 112a are shaped to protrude upwards at a position rearward of the vegetable compartment cover mounting portion 112b, which can restrict the position of the vacuum insulation material 12. Therefore, it is possible to prevent the vacuum insulation material 12 from being damaged by contact with the vegetable compartment cover mounting portion 112b. Furthermore, since the opposing surface of the lower surface recesses 112a opposite to the vacuum insulation material 12 on the rear side is an inclined surface 112c, it is also possible to suppress the vacuum insulation material 12 from being damaged by contact with the lower surface recesses 112a. In addition, since multiple lower surface recesses 112a are arranged in the left-right direction, and the lower surface recesses 112a are not formed continuously across the entire area in the left-right direction, the polyurethane insulation material can easily flow in, which, as a result, can improve the support strength of the front side of the insulation partition 11.

[0118] The heater 113 heats the vegetable compartment 6 facing the heat-insulating partition 11 (lower shell 112), maintaining the vegetable compartment 6 at a predetermined temperature zone. Although not shown, it is configured to include heat-conducting wires, an aluminum plate covering the heat-conducting wires, and leads connected to the heat-conducting wires. In this embodiment, the planar heater 113 cannot form a bend 12a like the vacuum insulation material 12, making it difficult to extend forward to the inclined surface 112c of the lower surface recess 112a. However, since the vacuum insulation material 12 is also located above the area in front that the heater 113 cannot reach, condensation can be prevented.

[0119] In this embodiment, since there is an area above the lower shell 112 that is not filled with the foamed insulation material 9, located behind the lower surface recess 112a, there is a possibility that the lower shell 112 may sag due to its own weight and bending. However, since the vegetable compartment 6 facing the lower shell 112 has a pull-out container, and the lower surface of the insulation partition 11 is difficult for the user to see, in this embodiment, the adverse effect on aesthetics can be suppressed, and the amount of foamed insulation material 9 filled can be reduced.

[0120] As described above, in this embodiment, the heat insulation partition 11 has an upper surface recess 111a of the upper shell 111 and a lower surface recess 112a of the lower shell 112. Here, since the temperature zone of the lower freezer compartment 5, which faces the upper shell 111, is lower than the temperature zone of the vegetable compartment 6, which faces the lower shell 112, it is necessary to increase the circulation flow rate of the cold air. Therefore, by making the overall recessed volume of the upper surface recess 111a larger than the overall recessed volume of the lower surface recess 112a, it is possible to prioritize ensuring the duct size of the cold air flowing at the bottom of the lower freezer compartment 5.

[0121] Temporary Cable Storage Department

[0122] Figure 22 This is a top view (viewed from above, on the side of the lower freezer compartment 5) of the insulated partition 11, excluding the upper shell 111. Figure 23 yes Figure 22 A partially enlarged perspective view of the dashed section F. For wires such as the leads of the heater 113 that pass through the insulation partition 11, they need to be positioned at a predetermined location before assembling the insulation partition 11 into the insulation housing and injecting the polyurethane foam insulation material. Therefore, in this embodiment, to improve workability when assembling the insulation partition 11 into the insulation housing, a temporary wire storage section 11b is formed on the front side of the lower shell 112 as a concave space for temporarily storing the wires. During the assembly of the insulation partition 11, the temporarily stored wires are removed from the temporary wire storage section 11b, connected to the predetermined position, and the polyurethane insulation material is injected and foamed.

[0123] like Figure 23As shown, the temporary wire storage section 11b is divided by an inner wall 11b1 to prevent damage to the wires from contact with the vacuum insulation material 12 and an outer wall 11b2 to prevent the wires from being pulled outwards. The inner wall 11b1 has multiple inner walls in the front-rear direction, with an inner opening 11b3 formed therebetween, allowing polyurethane insulation material to flow in through the inner opening 11b3. On the other hand, a first outer opening 11b4 is formed on the rear side of the outer wall 11b2, allowing wires to be introduced into the temporary wire storage section 11b. Furthermore, a second outer opening 11b5 is formed on the front side of the outer wall 11b2, opposite to the inner opening 11b3, allowing polyurethane insulation material injected into the insulation partition 11 from the polyurethane inlet 11a to easily pass into the temporary wire storage section 11b. Furthermore, a polyurethane inlet 11a is formed not only opposite the second outer opening 11b5 but also opposite the first outer opening 11b4, so the polyurethane insulation material also flows in from the first outer opening 11b4. Thus, the temporary wire storage portion 11b is formed facing the polyurethane inlet 11a towards the insulation partition portion 11, and the concave space is filled with foamed insulation material 9 to ensure insulation.

[0124] Furthermore, the inner wall 11b1 of the temporary wire storage section 11b also serves to limit the position of the vacuum insulation material 12 in a way that prevents the vacuum insulation material 12 from blocking the polyurethane inlet 11a. Additionally, the inner wall 11b1 and outer wall 11b2 extend upwards from the lower shell 112, but preferably do not contact the upper shell 111. This suppresses heat conduction between storage chambers located in different temperature zones above and below the insulation partition 11. Moreover, in this embodiment, the inner wall 11b1 and outer wall 11b2 are formed on the lower shell 112, but even when the inner wall 11b1 and outer wall 11b2 are formed on the upper shell 111 and extend downwards, heat conduction via the insulation partition 11 can be suppressed by separating the lower ends of the inner wall 11b1 and outer wall 11b2 from the lower shell 112.

[0125] Example 2

[0126] use Figure 24 The refrigerator 1 of Embodiment 2 will be described. In this embodiment, the top plate 16 as in Embodiment 1 is not provided, and the inner box 8 is fixed to the vacuum insulation material 12 using adhesive 18.

[0127] As described above, existing refrigerators fill the space between the vacuum insulation material 12 at the top and the inner box 8 with foamed insulation material 9, thus the inner box 8 is fixedly installed on the vacuum insulation material 12. Therefore, even with the weight of the inner box 8 and the linear expansion of the inner box 8 at high temperatures, there is essentially no sagging of the inner box 8. However, without foamed insulation material 9 filling the space between the vacuum insulation material 12 and the inner box 8, the inner box 8 is prone to bending and sagging. Therefore, in this embodiment, as... Figure 24 As shown, the vacuum insulation material 12 and the inner box 8 are fixed by an adhesive 18 such as hot melt adhesive to suppress the sagging of the inner box 8. Furthermore, the adhesive 18 used is preferably a material that can elastically deform in a manner that follows the flexing of the inner box 8.

[0128] Furthermore, if only adhesive 18 is used, there is a possibility that the vacuum insulation material 12 and the inner box 8 may peel off due to the inability to keep up with the bending of the inner box 8. Moreover, since the vacuum insulation material 12 has variations in thickness, warping, and surface unevenness, the inner box 8 and adhesive 18 will inevitably also have thickness variations. Therefore, in this embodiment, in order to absorb the bending of the inner box 8 and the dimensional variations of each component and maintain a constant gap between the vacuum insulation material 12 and the inner box 8, a gasket 19 is provided between the outer box 7 and the vacuum insulation material 12. The gasket 19 is a clamping component with a certain thickness and has the function of joining the outer box 7 and the vacuum insulation material 12; for example, a double-sided tape formed into a sheet shape using polyethylene or the like can be used. Furthermore, if the thickness is guaranteed, an adhesive such as hot melt adhesive can also be used as the gasket 19. Furthermore, the gasket 19 does not need to be provided on the entire upper surface of the vacuum insulation material 12; it is preferably provided in at least a portion or all of the area without polyurethane.

[0129] Furthermore, compared to the vacuum insulation material 12, the inner box 8 and the foamed insulation material 9 are more prone to deformation with temperature changes. Therefore, elastic components can be used to cover and protect the front, back, left, and right sides of the vacuum insulation material 12, preventing damage to the vacuum insulation material 12 due to deformation of the inner box 8, etc. In addition, in the vertical direction of the vacuum insulation material 12, the pad 19 acts as a buffer, filling the gaps between the vacuum insulation material 12 and the outer box 7 and the inner box 8, and preventing damage to the vacuum insulation material 12.

[0130] Example 3

[0131] As described above, the refrigerator 1 of Embodiment 1 and Embodiment 1 achieves partial polyurethane-free insulation of the inner box, and fills the front side of the insulation box with foamed insulation material 9 to maintain strength. That is, in the top, side and bottom surfaces of the inner box 8, the distance between the inner box and the vacuum insulation material 12 is increased in the front region and decreased in the central region. Therefore, there is a portion where the size of the rear inner box 8 is larger than that of the front inner box 8. In this way, when mass-producing refrigerators of the same model 1, even if multiple inner boxes 8 are stacked for storage, it is difficult for one inner box 8 to touch and be embedded in the narrow opening of another inner box 8. Therefore, in this embodiment, the area in the inner box 8 that is at least partially polyurethane-free, that is, the area where the size of the rear side is increased compared to the front side, can be deformed by corrugated structure or the like. As a result, when multiple inner boxes 8 are stacked, they can be stored by shrinking, and when the polyurethane insulation material is foamed, they can be unfolded by being pushed from the inside by clamps.

[0132] This invention is not limited to the embodiments described above and can be modified in various ways. For example, in Embodiment 1, a top plate 16 is provided below the inner box 8 at the top. Alternatively, instead of providing a top plate 16, the lampshade inside the box can be configured to expand rearward to cover the lower part of the inner box 8. Furthermore, the embodiments described above are illustrative examples for the purpose of easily understanding and explaining the invention, and are not limited to having all the structures described. Moreover, a part of the structure of one embodiment can be replaced with the structure of another embodiment, and the structure of another embodiment can be added to the structure of one embodiment. Furthermore, it is also possible to add, delete, or replace other structures in a part of the structure of each embodiment.

[0133] <Technical concepts contained in this specification>

[0134] This specification contains the following technical concepts.

[0135] [Postscript 1-1]

[0136] A refrigerator includes a cabinet forming a storage compartment with a front opening. Foamed insulation material is used to fill the area between the inner and outer cabinets. The vertical dimension of the cabinet is larger than its horizontal dimension.

[0137] The left and / or right sides of the box are configured as follows:

[0138] The front end has a front insulation material that is continuously foamed and filled with the aforementioned foamed insulation material in the vertical direction.

[0139] It has a smaller area where the foamed insulation material can flow compared to the surrounding area.

[0140] Furthermore, it possesses other insulation materials with higher insulation performance than the aforementioned foamed insulation materials.

[0141] [Notes 1-2]

[0142] Based on Appendix 1-1, the refrigerator is configured as follows:

[0143] In the aforementioned region with a relatively small thickness that allows for flow, there is a portion that recesses the inner box toward the outer box.

[0144] [Notes 1-3]

[0145] Based on notes 1-2, the refrigerator is configured as follows:

[0146] The aforementioned left and right sides are equipped with shelf ribs or guide rails.

[0147] The aforementioned flowable, thinner region is located above the uppermost shelf rib or below the lowermost guide rail.

[0148] [Notes 1-4]

[0149] Based on notes 1-2, the refrigerator is configured as follows:

[0150] The aforementioned left and right sides are equipped with shelf ribs or guide rails.

[0151] At the upper and lower positions of any of the aforementioned shelf ribs or guide rails, there is a region with a relatively small thickness that is capable of flow at a position forward of the front end of the shelf rib or guide rail.

[0152] [Notes 1-5]

[0153] Based on notes 1-2, the refrigerator is configured as follows:

[0154] The aforementioned left and right sides are equipped with shelf ribs or guide rails.

[0155] The aforementioned shelf ribs or guide rails are arranged in multiple vertical rows.

[0156] The area held between the shelf ribs or the guide rails has a relatively thin region that allows for flow.

[0157] [Notes 1-6]

[0158] Based on notes 1-5, the refrigerator is configured as follows:

[0159] The aforementioned shelf ribs or guide rails were reinforced respectively.

[0160] [Notes 1-7]

[0161] Based on notes 1-2, the refrigerator is configured as follows:

[0162] The aforementioned left and right sides are equipped with shelf ribs or guide rails.

[0163] The thickness of the foamed insulation material that can flow from the front end of the aforementioned shelf rib or guide rail toward the front end insulation material has a relatively large range.

[0164] The area overlapping with the aforementioned shelf ribs or guide rails is filled with foamed insulation material.

[0165] [Notes 1-8]

[0166] Based on notes 1-2, the refrigerator is configured as follows:

[0167] No shelf ribs or guide rails are provided on the aforementioned left and right sides.

[0168] On the left and right sides, respectively, there is a region of relatively small thickness that allows for flow at a position one-third of the front-to-back dimension from the front end to the back of the inner box, near the rear end.

[0169] [Notes 1-9]

[0170] Based on notes 1-2, the refrigerator is configured as follows:

[0171] In the aforementioned flowable, thinner areas, there are portions that are not filled with the aforementioned foamed insulation material.

[0172] [Notes 1-10]

[0173] Based on notes 1-2, the refrigerator is configured as follows:

[0174] The aforementioned flowable, thinner region is formed within the projection plane of the other insulation materials in a region that is more inward than the edge of the other insulation materials.

[0175] [Postscript 1-11]

[0176] Based on any one of Appendix 1-1 to Appendix 1-10, the refrigerator is configured as follows:

[0177] Foamed insulation material is continuously filled at the front end of the top and / or bottom surface of the aforementioned housing, along with the aforementioned front end insulation material.

[0178] [Postscript 1-12]

[0179] Based on notes 1-2, the refrigerator is configured as follows:

[0180] In the top surface of the aforementioned housing, the aforementioned foamed insulation material is not located on at least a portion of the lower surface of the other aforementioned insulation materials.

[0181] The aforementioned inner casing is fixed to the lower surface of the other insulation materials using an adhesive.

[0182] [Postscript 1-13]

[0183] Based on notes 1-12, the refrigerator is configured as follows:

[0184] A pad is provided between the upper surface of the other insulation materials and the outer casing.

[0185] [Postscript 1-14]

[0186] Based on notes 1-12, the refrigerator is configured as follows:

[0187] In the top surface of the aforementioned housing, the aforementioned foamed insulation material is not located on at least a portion of the lower surface of the other aforementioned insulation materials.

[0188] In the area where the aforementioned foamed insulation material is not located on the lower surface of the other insulation materials, a top plate is provided below the aforementioned inner box.

[0189] [Postscript 1-15]

[0190] Based on Appendix 1-12 or Appendix 1-14, the refrigerator is configured as follows:

[0191] In the top surface of the aforementioned housing, the aforementioned foamed insulation material is located on the front, back, left, and right sides of the aforementioned other insulation materials.

[0192] [Postscript 1-16]

[0193] Based on notes 1-12, the refrigerator has the following features:

[0194] Other storage rooms with a temperature zone lower than that of the aforementioned storage rooms; and

[0195] An insulated partition that separates the aforementioned storage room from the other aforementioned storage rooms.

[0196] The aforementioned thermal insulation partition contains a foamed thermal insulation material and other thermal insulation materials with higher thermal insulation performance than the foamed thermal insulation material.

[0197] Regarding the aforementioned thermal insulation partition, there exists an area in the projection plane from the aforementioned storage room toward the aforementioned other storage rooms where the thickness of the foamed thermal insulation material is smaller than that of the surrounding area.

[0198] [Postscript 1-17]

[0199] Based on notes 1-16, the refrigerator is configured as follows:

[0200] In the aforementioned areas with a relatively small flow thickness, there are portions that are not filled with the aforementioned foamed insulation material.

[0201] [Postscript 1-18]

[0202] Based on notes 1-16, the refrigerator is configured as follows:

[0203] In the aforementioned areas where the flow thickness is relatively small, a recess is provided at least on the surface of the aforementioned insulating partition that is opposite to the other storage compartments.

[0204] [Postscript 2-1]

[0205] A refrigerator has a cabinet with vacuum insulation material and foam insulation material between the outer and inner cabinets.

[0206] In the top surface of the housing, the foamed insulation material is located on the front, back, left and right sides of the vacuum insulation material, and the foamed insulation material is not located on at least a portion of the lower surface of the vacuum insulation material.

[0207] [Postscript 2-2]

[0208] Based on Appendix 2-1, the refrigerator is configured as follows:

[0209] The aforementioned foamed insulation material is located in the front and rear regions of the lower surface of the aforementioned vacuum insulation material.

[0210] [Notes 2-3]

[0211] Based on Appendix 2-1, the refrigerator is configured as follows:

[0212] The aforementioned top surface has an internal light.

[0213] Wiring for the internal light is provided in the area where the foam insulation material is filled on the lower surface of the aforementioned vacuum insulation material.

[0214] [Appendix 2-4]

[0215] Based on Appendix 2-1, the refrigerator is configured as follows:

[0216] In the area where the aforementioned foamed insulation material is not located on the lower surface of the aforementioned vacuum insulation material, a top plate is provided below the aforementioned inner box.

[0217] [Notes 2-5]

[0218] Based on Appendix 2-1, the refrigerator is configured as follows:

[0219] The inner box is fixed relative to the lower surface of the vacuum insulation material using an adhesive different from that used for the foamed insulation material.

[0220] [Appendix 2-6]

[0221] Based on Appendix 2-5, the refrigerator is configured as follows:

[0222] A pad is provided between the upper surface of the aforementioned vacuum insulation material and the aforementioned outer casing.

[0223] Symbol Explanation

[0224] 1—Refrigerator, 2—Refrigerator compartment, 3—Ice maker, 4—Upper freezer compartment, 5—Lower freezer compartment, 6—Vegetable compartment, 7—Outer casing, 8—Inner casing, 9—Foamed insulation material, 10, 11—Insulation partition, 11a—Polyurethane inlet, 11b—Temporary cable storage, 111—Upper shell, 111a—Upper surface recess, 111b—Bridging part, 112—Lower shell, 112a—Lower surface recess, 113—Heater, 12—Vacuum insulation material, 13—Shelf rib, 14—Interior light, 15—Wire, 16—Top plate, 17—Threaded parts, 18—Adhesive, 19—Padding, 21—Guide rail, 22—Hinge, 23—Reinforcing parts.

Claims

1. A refrigerator, characterized in that, have: The enclosure forms a storage compartment with a front opening. Foamed insulation material is used to fill the area between the inner and outer enclosures. The vertical dimensions of the enclosure are larger than its horizontal dimensions. Ribs, which are arranged on the left and right sides of the aforementioned inner box within the aforementioned storage compartment, and retain the shelves, A front-end insulation material is formed by foaming and filling the first region of the foamed insulation material in the front end and throughout the vertical direction on the left side and / or the right side. In a region located rearward from the first region and above the uppermost rib, a second region is formed where the inner box is recessed towards the outer box than the first region. A third region is formed by the area between the first region and the front end of the rib, and the area further back than the first region and sandwiched between the rib from above and below. An injection port is located on the back of the aforementioned outer casing. Other insulation materials with higher thermal insulation performance than the aforementioned foamed insulation materials. Compared to the third region, the second region has a smaller or no filling thickness of the foamed insulation material.

2. The refrigerator according to claim 1, characterized in that, The aforementioned ribs or the guide rails located on the aforementioned left and right sides have been reinforced.

3. The refrigerator according to claim 2, characterized in that, The thickness of the foamed insulation material that can flow from the front end of the aforementioned rib or guide rail toward the front end of the insulation material is relatively large. The area overlapping with the aforementioned ribs or guide rails is filled with foamed insulation material.

4. The refrigerator according to claim 1, characterized in that, The first region, the second region, and the third region are formed within the projection plane of the other insulation materials in regions that are more inward than the edge of the other insulation materials.

5. The refrigerator according to any one of claims 1 to 4, characterized in that, Foamed insulation material is continuously filled at the front end of the top and / or bottom surface of the aforementioned housing, along with the aforementioned front end insulation material.

6. The refrigerator according to claim 1, characterized in that, In the top surface of the aforementioned housing, the aforementioned foamed insulation material is not located on at least a portion of the lower surface of the other aforementioned insulation materials. The aforementioned inner casing is fixed to the lower surface of the other insulation materials using an adhesive.

7. The refrigerator according to claim 6, characterized in that, A pad is provided between the upper surface of the other insulation materials and the outer casing.

8. The refrigerator according to claim 1, characterized in that, In the top surface of the aforementioned housing, the aforementioned foamed insulation material is not located on at least a portion of the lower surface of the other aforementioned insulation materials. In the area where the aforementioned foamed insulation material is not located on the lower surface of the other insulation materials, a top plate is provided below the aforementioned inner box.

9. The refrigerator according to claim 6 or 8, characterized in that, In the top surface of the aforementioned housing, the aforementioned foamed insulation material is located on the front, back, left, and right sides of the aforementioned other insulation materials.

10. The refrigerator according to claim 1, characterized in that, have: Other storage rooms with a temperature zone lower than that of the aforementioned storage rooms; and An insulated partition that separates the aforementioned storage room from the other aforementioned storage rooms. The aforementioned thermal insulation partition contains a foamed thermal insulation material and other thermal insulation materials with higher thermal insulation performance than the foamed thermal insulation material. Regarding the aforementioned thermal insulation partition, there exists an area in the projection plane from the aforementioned storage room toward the aforementioned other storage rooms where the thickness of the foamed thermal insulation material is smaller than that of the surrounding area.

11. The refrigerator according to claim 10, characterized in that, In the aforementioned areas with a relatively small flow thickness, there are portions that are not filled with the aforementioned foamed insulation material.

12. The refrigerator according to claim 10, characterized in that, In the aforementioned areas where the flow thickness is relatively small, a recess is provided at least on the surface of the aforementioned insulating partition that is opposite to the other storage compartments.

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