Refrigerator and method for manufacturing refrigerator door

Abstract

The invention relates to a refrigerator and a method for manufacturing a refrigerator door. The door panel component can be installed on the end part component while the unexpected deformation of the door panel component is restrained. The refrigerator is characterized in that the refrigerator is provided with a door (44) arranged on the refrigerator body, and the door (44) is provided with a door face component (50) forming the front surface of the outer side of the refrigerator and end components (60 and 75) installed at the ends of the door face component (50). The door surface member (50) is provided with a first end surface (52) protruding rearward from a first end edge (50a) of the front surface (51), and a first attachment surface (55) protruding inward in the width direction from an upper edge or a lower edge of the first end surface (52), and the end members (60, 75) are provided with openings (66a) into which the first attachment surface (55) is inserted. A front end portion (62a) forming an opening portion (66a) on the inner side of the door (44) is arranged away from the first end face (52) towards the inner side in the width direction.

Description

Technical Field

[0001] Embodiments of the present invention relate to a refrigerator and a method for manufacturing a door for a refrigerator. Background Art

[0002] A door of a refrigerator is composed of a door face member that forms the front surface on the outer side of the refrigerator cabinet, a door inner panel that forms the rear surface on the inner side of the cabinet, and end members that form the upper and lower ends of the door, and is filled with a foamed heat insulating material inside (for example, refer to Patent Document 1).

[0003] In such a door, sometimes the end of the door face member is bent toward the inside of the door, and the bent front end portion is inserted into the end member to attach the end member to the door face member. By inserting the bent front end portion into the end member, it is possible to suppress the protrusion of the end member on the front surface and side surface of the door, and improve the appearance.

[0004] Patent Document 1: Japanese Unexamined Patent Application Publication No. 2022-47871

[0005] However, if the front end portion bent toward the inside of the door is to be inserted into the end member, it is necessary to manually re-bend the door face member so as to unfold it, etc., and strain generated due to repeated deformation may remain in the door face member. Summary of the Invention

[0006] An object of the present invention is to provide a refrigerator capable of attaching a door face member to an end member while suppressing the generation of strain.

[0007] A refrigerator according to an embodiment of the present invention includes a refrigerator main body having a storage chamber inside, and a door provided on the refrigerator main body. In this refrigerator, the door includes a door face member that forms the front surface on the outer side of the cabinet, and an end member attached to an end of the door face member. The door face member includes a first end face that protrudes rearward from a first end edge of the front surface, and a first mounting surface that protrudes inward in the width direction from an upper edge portion or a lower edge portion of the first end face. The end member includes an opening for inserting the first mounting surface, and a front end portion of the opening formed on the inner side of the door is provided so as to be separated from the first end face inward in the width direction.

[0008] Advantages of the Invention

[0009] According to the refrigerator of the present invention, it is possible to attach the door face member to the end member while suppressing the generation of strain. Brief Description of the Drawings

[0010] Figure 1 is a longitudinal sectional view of the refrigerator.

[0011] Figure 2 Front view of the refrigerator.

[0012] Figure 3 It is a perspective view showing the door from the upper front obliquely.

[0013] Figure 4 It is a perspective view showing the door from the upper rear obliquely.

[0014] Figure 5 It is a sectional view of the door.

[0015] Figure 6 It is a perspective view showing the front door panel from the upper rear obliquely.

[0016] Figure 7 It is a top view of the front door panel.

[0017] Figure 8 It is a perspective view showing the main part of the front door panel from the upper front obliquely.

[0018] Figure 9A It is a front view of the upper end part.

[0019] Figure 9B It is a perspective view of the upper end part.

[0020] Figure 10A It is Figure 9A the A - A sectional view of

[0021] Figure 10B It is a top view schematically showing the end part and the door surface member with the outer part omitted.

[0022] Figure 11 It is a perspective view observing the right end of the upper end part from the lower front obliquely.

[0023] Figure 12 It is an enlarged front view of the main part of the upper end part showing the first protrusion.

[0024] Figure 13 It is a right side view of the upper end part.

[0025] Figure 14 It is a view observing the left end of the upper end part from the rear obliquely.

[0026] Figure 15A It is Figure 11 the sectional view of the door at the position corresponding to B - B in

[0027] Figure 15B and it is a view with the support member and the heat insulation material omitted. Figure 15A It is a view showing the main part of

[0028] Figure 16A It is Figure 11Cross-sectional view of the door at the position corresponding to C-C in [reference], and the view omitting the support member and the heat insulation material.

[0029] Figure 16B It is a view that Figure 16A magnifies and shows the main part.

[0030] Figure 17 It is a view corresponding to Figure 11 Cross-sectional view of the door at the position corresponding to D-D in [reference], and the view omitting the support member and the heat insulation material.

[0031] Figure 18 It is a perspective view showing the lower end part from the obliquely front upper side.

[0032] Figure 19A It is a perspective view showing the state where the support member is installed on the upper end part from the obliquely rear lower side.

[0033] Figure 19B It is a perspective view showing the state before installing the support member on the upper end part from the obliquely rear lower side.

[0034] Figure 20 It is a view corresponding to Figure 11 Cross-sectional view of the door at the position corresponding to C-C in [reference], and the view omitting the heat insulation material.

[0035] Figure 21 It is a view showing the steps of installing the end part on the door surface member.

[0036] Figure 22 It is a view that Figure 21 magnifies the main part of (c).

[0037] Figure 23 It is a view that Figure 21 magnifies the main part of (d).

[0038] Figure 24 It is a view showing the middle of installing the end part on the door surface member, and the view showing the state where the first installation surface is inserted into the first storage part.

[0039] Figure 25 It is a bottom view of the end part.

[0040] Figure 26 It is a perspective view of the support member.

[0041] Figure 27 It is an exploded perspective view of the end part and the support member.

[0042] Figure 28 It is a bottom view of the end part and the support member showing a modification example.

[0043] Figure 29is a cross-sectional view at a position corresponding to A4 - A4 in Figure 28 and is a cross-sectional view at a position corresponding to A5 - A5 in

[0044] Figure 30 is a cross-sectional view at a position corresponding to A5 - A5 in Figure 28 and is a cross-sectional view at a position corresponding to A5 - A5 in

[0045] Figure 31 is a top view showing the end member and the door face member with the outer portion omitted in Modification Example 1.

[0046] Figure 32 is a top view showing the end member and the door face member with the outer portion omitted in another Modification Example 1.

[0047] Figure 33 is a view showing the arrangement of the support members in the refrigerator of Modification Example 3.

[0048] Figure 34 is a view showing the arrangement of the support members in the refrigerator of Modification Example 4.

[0049] Explanation of Reference Numerals

[0050] 2: Refrigerator main body, 10: Refrigerator, 44: Small refrigerating chamber door, 50: Door face member, 50a: First end edge, 50b: First rear end edge, 50c: Second end edge, 50d: Second rear end edge, 51: Front portion, 52: First end face portion, 53: First rear face portion, 53a: First through hole, 54: Third mounting surface, 55: First mounting surface, 56: Second end face portion, 57: Second rear face portion, 57a: Second through hole, 58: Second mounting surface, 60: End member, 61: Outer portion, 61a: Handle portion, 61a1: Left inner wall, 61a2: Right inner wall, 62: First protrusion, 62a: Front end portion, 62b: First inclined portion, 63: Second protrusion, 63a: Transverse protrusion, 63a1: Front end portion, 63b: Transverse groove inner protrusion, 63b1: Second inclined portion, 63c: Transverse opposed protrusion, 63c1: Front end portion, 64: Third protrusion, 64a: Front protrusion, 64a1: Front end portion, 64b: Front groove inner protrusion, 64b1: Third inclined portion, 64c: Front opposed protrusion, 64c1: Front end portion, 65: Rear wall, 65a: First covering portion, 65a1: First engaging protrusion, 65b: Second covering portion, 65b1: Outer covering portion, 65b2: Inner covering portion, 65b3: Second engaging protrusion, 66: First storage portion, 66a: Opening portion, 67: Second storage portion, 67a: Second opening portion, 68: Third storage portion, 68a: Third opening portion, 69: Flexible body, 70: Flexible body, 71: Locking claw, 90: Fixing device, 100: Inner door panel, 102: Heat insulating material Detailed Description of the Invention

[0051] The embodiments will be described with reference to the drawings.

[0052] (1) Configuration of the refrigerator 10

[0053] Figure 1 And Figure 2 The refrigerator 10 showing the embodiments. The housing 11 of the refrigerator 10 has an outer box 12 that forms the outer contour of the refrigerator 10, an inner box 13 combined with the outer box 12, and a heat insulation part 14 between the outer box 12 and the inner box 13. A heat insulation material is filled in the heat insulation part 14. The outer box 12 and the inner box 13 sandwich the heat insulation material.

[0054] The inside of the housing 11 is vertically partitioned by a heat insulation partition wall 21. Above the heat insulation partition wall 21 is a refrigerating space. The refrigerating space is maintained at a temperature suitable for refrigerated storage, that is, a refrigerating temperature. In addition, below the heat insulation partition wall 21 is a freezing space. The freezing space is maintained at a temperature suitable for frozen storage, that is, a freezing temperature.

[0055] A plurality of storage chambers for storing food are provided in the refrigerating space and the freezing space respectively. Each storage chamber has an opening in the front, and the user can take out and put in food from the opening.

[0056] In the refrigerating space, a refrigerating chamber 20 and a vegetable chamber 22 as storage chambers are provided in order from above. A plurality of mounting racks 24 are provided in the refrigerating chamber 20. The periphery of the mounting racks 24 in the refrigerating chamber 20 is maintained within the range of the refrigerating temperature, for example, 2 to 5 °C. A quick-freezing chamber 26 is provided at the lower part in the refrigerating chamber 20. The quick-freezing chamber 26 is a place that is particularly maintained at a low temperature inside the refrigerating chamber 20, for example, maintained at 0 to 3 °C.

[0057] The front opening of the refrigerating chamber 20 is opened and closed by a pair of left and right refrigerating chamber doors 40, 41. The refrigerating chamber doors 40, 41 are rotary doors that are pivotally supported rotatably by hinges (not shown) provided on the left and right sides of the refrigerator main body 2. An operation panel 15 is provided on one of the refrigerating chamber doors 40. The operation panel 15 is a part for the user to operate the refrigerator 10 and is also a part for displaying necessary information to the user. A plurality of storage door pockets 29 are provided on the inner surface of the refrigerating chamber door 40 on the box side.

[0058] The vegetable chamber 22 is maintained within the range of the refrigerating temperature, for example, 4 to 7 °C. A pull-out storage container is stored in the vegetable chamber 22. The front opening of the vegetable chamber 22 is opened and closed by a pull-out vegetable chamber door 42.

[0059] An ice making chamber (not shown) is provided on the upper left side of the freezing space. In addition, a small freezing chamber 27 is provided on the upper right side of the freezing space (on the right side of the ice making chamber). A freezing chamber 28 is provided below the ice making chamber and the small freezing chamber 27. Drawer-type storage containers are respectively stored in the ice making chamber, the small freezing chamber 27, and the freezing chamber 28. The interiors of the ice making chamber, the small freezing chamber 27, and the freezing chamber 28 are maintained within the range of freezing temperature, such as -20 to -18°C, during normal operation.

[0060] The front opening of the ice making chamber is opened and closed by a drawer-type ice making chamber door 43. In addition, the front opening of the small freezing chamber 27 is opened and closed by a drawer-type small freezing chamber door 44. In addition, the front opening of the freezing chamber 28 is opened and closed by a drawer-type freezing chamber door 45.

[0061] A first cooling chamber 35 is provided behind the refrigerating space. The first cooling chamber 35 is a space formed between the inner box 13 of the housing 11 and the wall 19 constituting the back of the storage chamber. A first cooler 30 that generates cold air and a first fan 32 as a blowing device that circulates the generated cold air are provided in the first cooling chamber 35. The cold air generated by the first cooler 30 is blown into the refrigerating space through a pipe 31 extending upward from the first cooler 30 and circulates in the refrigerating space. The cold air that has circulated in the refrigerating space returns to the location of the first cooler 30.

[0062] In addition, a second cooler 33 that generates cold air and a second fan 34 as a blowing device that circulates the generated cold air are provided behind the freezing space. The cold air generated in the second cooler 33 is blown into the freezing space and circulates in the freezing space, and then returns to the location of the second cooler 33.

[0063] A mechanical chamber 36 is provided at the rear lower part of the refrigerator 10. A compressor 37, a condenser (not shown), etc. are stored in the mechanical chamber 36. The compressor 37, the condenser, the first cooler 30, the second cooler 33, etc. constitute a known refrigeration cycle device. The refrigerant compressed by the compressor 37 alternately flows into the first cooler 30 and the second cooler 33, and thus cold air is alternately generated by the first cooler 30 and the second cooler 33.

[0064] (2) Structure of the door

[0065] Next, the structure of the door of the present embodiment will be described. Although the vegetable chamber door 42, the ice making chamber door 43, the small refrigerating chamber door 44, and the refrigerating chamber door 45 have different sizes and shapes, they have the same structure. Therefore, here, the small refrigerating chamber door 44 (hereinafter simply referred to as "door 44") will be taken as an example for description.

[0066] In the following description, left and right, front and back, and up and down represent the appearance when the refrigerator 10 is observed from the front. Further, the center side in the left-right direction in the door 44 is defined as the "inner side in the width direction". In addition, the end side in the left-right direction in the door 44 is defined as the "outer side in the width direction". Further, the center side in the up-down direction in the door 44 is defined as the "inner side in the up-down direction of the door". In addition, the end side in the up-down direction in the door 44 is defined as the "outer side in the up-down direction of the door".

[0067] As will be described later, the structure of the door 44 is different on the left and right. The left side of the door 44 is the ice-making chamber side, which is another storage chamber. As Figure 3 ~ As Figure 5 shown, the door 44 includes a front door face member 50, a rear door inner panel 100, upper and lower end members 60 and 75 respectively, a support member 180 fixed to the upper end member 60 (refer to Figure 19A , Figure 19B and Figure 20 ), a support member (not shown) fixed to the lower end member 75, and a heat insulating material 102 filled between the door face member 50, the door inner panel 100 and the upper and lower end members 60 and 75.

[0068] (3) Door face member 50

[0069] The door face member 50 is formed by bending a metal plate such as a steel plate, and constitutes the front, side and left and right side edges of the back of the door 44.

[0070] Specifically, as Figure 6 ~ As Figure 8 shown, the door face member 50 includes: a substantially rectangular front face portion 51, which is the portion constituting the front surface of the door 44 and is surrounded by an upper end edge, a lower end edge, a left end edge and a right end edge; a first end face portion 52, which protrudes rearward from one end edge (for example, the right end edge) 50a of the front face portion 51; a first rear face portion 53, which protrudes inward in the width direction from the rear end edge (hereinafter, this edge may also be referred to as the first rear end edge) 50b of the first end face portion 52; a second end face portion 56, which protrudes rearward from the second end edge (for example, the left end edge) 50c of the front face portion 51 that faces the first end edge 50a; and a second rear face portion 57, which extends inward in the width direction from the rear end edge (hereinafter, this edge may also be referred to as the second rear end edge) 50d of the second end face portion 56. The protruding amount of the first rear face portion 53 protruding inward in the width direction from the first end face portion 52 is greater than the protruding amount of the second rear face portion 57 protruding inward in the width direction from the second end face portion 56. In addition, the first end face portion 52 corresponds to the "first end face" of the present invention.

[0071] Further, the facade member 50 includes a first mounting surface 55, a second mounting surface 58, and a third mounting surface 54 for mounting to the end members 60 and 75. The first mounting surface 55 is a portion that protrudes inward in the width direction from the end connecting the front portion 51 and the first rear portion 53, respectively, above and below the first end face portion 52. In addition, the second mounting surface 58 is a portion that protrudes inward in the width direction from the end connecting the front portion 51 and the second rear portion 57, respectively, above and below the second end face portion 56. In addition, the third mounting surface 54 is a portion that protrudes rearward from the respective upper and lower end edges of the front portion 51. At the front portion 51, the first end face portion 52 is connected to the right end edge, the second end face portion 56 is connected to the left end edge, and the third mounting surfaces 54 are connected to the upper and lower end edges other than the right and left end edges, respectively.

[0072] In addition, the basic structures of the upper end portion and the lower end portion of the facade member 50 are the same. That is, the first mounting surface 55, the second mounting surface 58, the third mounting surface 54, the first rear portion 53, and the second rear portion 57 have the same structure between the upper end portion and the lower end portion of the facade member 50. Therefore, the upper end portion of the facade member 50 will be described here, and for the constitution of the lower end portion, the corresponding constitutions are denoted by the same reference numerals and detailed descriptions are omitted.

[0073] As Figure 7 and Figure 8 shown, the front end portion 55a of the first mounting surface 55 is connected to the end portion (hereinafter also sometimes referred to as the right end portion) 54a on the first end edge 50a side of the third mounting surface 54 through a first connecting portion 55d protruding from the upper end of the first end edge 50a. The rear end portion 55b of the first mounting surface 55 is connected to the upper end portion of the first rear portion 53 through a first protruding portion 55e. The first protruding portion 55e protrudes inward in the width direction from the first end face portion 52, connecting the rear end portion 55b of the first mounting surface 55 to the first end face portion 52 side of the first rear portion 53, forming the corner portion at the upper right rear side of the facade member 50.

[0074] In addition, the front end portion 58a of the second mounting surface 58 is connected to the end portion (hereinafter also sometimes referred to as the left end portion) 54b on the second end edge 50c side of the third mounting surface 54 through a second connecting portion 58d protruding from the upper end of the second end edge 50c. The rear end portion 58b of the second mounting surface 58 is connected to the upper end portion of the second rear portion 57 through a second protruding portion 58e. The second protruding portion 58e protrudes inward in the width direction from the second end face portion 56, connecting the rear end portion 58b of the second mounting surface 58 to the second end face portion 56 side of the second rear portion 57, forming the corner portion at the upper left rear side of the facade member 50.

[0075] Compared with the central portion 55c of the first mounting surface 55, the protruding amounts of the front end portion 55a, the rear end portion 55b, the first connecting portion 55d, and the first protruding portion 55e of the first mounting surface 55 from the first end surface portion 52 are smaller. The second mounting surface 58 is the same as the first mounting surface 55, and compared with the central portion 58c of the second mounting surface 58, the protruding amounts of the front end portion 58a, the rear end portion 58b, the second connecting portion 58d, and the second protruding portion 58e from the second end surface portion 56 are smaller. In addition, compared with the central portion 54c, the protruding amounts of the right end portion 54a and the left end portion 54b of the third mounting surface 54 from the front surface portion 51 are smaller.

[0076] As Figure 6 ~As Figure 8 shown, a first through hole 53a penetrating in the front-rear direction is provided at the upper end of the first rear surface portion 53. In addition, a second through hole 57a penetrating in the front-rear direction is provided at the upper end of the second rear surface portion 57. In addition, the first through hole 53a and the second through hole 57a may not only be holes whose edge portions are continuously connected, but may also be Figure 6 and Figure 8 notched holes with open edge portions as shown.

[0077] (4) Inner door panel 100

[0078] The inner door panel 100 is a molded product of synthetic resin. The inner door panel 100 constitutes the inner surface of the box in the door 44. Although not shown, gaskets with a known structure are mounted along the upper, lower, left, and right edges on the rear surface of the inner door panel 100.

[0079] (5) End members 60, 75

[0080] The upper and lower end members 60, 75 are molded products of synthetic resin. The upper end member 60 is joined to the door surface member 50 and the upper end portion of the inner door panel 100 to form the upper surface in the door 44. The lower end member 75 is joined to the door surface member 50 and the lower end portion of the inner door panel 100 to form the lower surface in the door 44.

[0081] Figure 9A , Figure 9B , Figures 10A to 14 represents the upper end member 60, Figure 15A , Figure 15B , Figure 16A , Figures 16B to 17 represents the state where the door surface member 50 is mounted on the end member 60. As Figure 5 , Figure 9A , Figure 9B , Figure 10A , Figure 10B shown, the end member 60 includes an outer surface portion 61, a first protrusion 62, a second protrusion 63, a third protrusion 64, and a rear wall 65.

[0082] As Figure 15A , Figure 15B , Figure 16A , Figures 16B to 17 shown, the outer surface portion 61 is a portion constituting the outer side of the door 44. In the end member 60 located on the upper side of the door 44, the outer surface portion 61 constitutes the upper surface side of the door 44. Similarly, in the end member 75 located on the lower side of the door 44, the outer surface portion constitutes the lower surface side of the door 44. Therefore, the end member 60 located on the upper side of the door 44 will be described here. In a state where the end member 60 is attached to the door surface member 50, the outer surface portion 61 is a portion that faces the first attachment surface 55 of the door surface member 50 on the right side of the door 44, faces the second attachment surface 58 on the left side of the door, and faces the third attachment surface 54 on the front side of the door 44. That is, the outer surface portion 61 is disposed outside the door vertical direction of the first attachment surface 55, the second attachment surface 58, and the third attachment surface 54 of the door surface member 50, and constitutes the upper surface side of the door 44.

[0083] As Figures 3 to 5 , Figure 9A and Figure 9B shown, a downwardly recessed handle portion 61a that functions as a handle portion of the door 44 is formed in the outer surface portion 61. The cross-sectional shape of the handle portion 61a is asymmetric in the left-right direction. The bottom shape of the handle portion 61a is such that it is a gentle slope on the right side in the left-right direction of the refrigerator 10, which is the outer side in the left-right direction, compared to the adjacent storage chamber side, which is the left side. That is, the left side of the handle portion 61a becomes a left inner wall 61a1 that extends substantially along the vertical direction, while the right side of the handle portion 61a becomes a right inner wall 61a2 formed by a gentle inclined surface formed by an inclined angle closer to the horizontal than the left side, resulting in a shape with less depression.

[0084] As Figure 9A , Figure 9B , Figure 11 shown, a first inner wall 161 and a second inner wall 162 are formed on the inner side in the door vertical direction on the right side of the upper end member 60 as walls that stand up toward the center in the door vertical direction and extend along the front-rear direction.

[0085] As Figure 9A , Figure 9B , Figures 10A to 14 , Figure 16A , Figure 16B shown, a first protrusion 62 is provided at one end (for example, the right end) in the left-right direction of the end member 60. The first protrusion 62 is provided at an interval from the right end of the outer surface portion 61 toward the inner side in the door vertical direction. The first protrusion 62 is constituted by, for example, a protrusion that protrudes outward in the width direction from the second inner wall 162, which stands up from the right end of the outer surface portion 61 toward the center in the door vertical direction and extends along the front-rear direction.

[0086] In the present embodiment, as Figures 10A to 13 shown, a plurality of first protrusions 62 are provided at intervals in the front-rear direction. Preferably, the front end of the first protrusion 62 provided on the front side is arranged behind the third protrusion 64, and the rear end of the first protrusion 62 provided on the rear side is arranged in front of the rear wall 65 provided at the rear end of the end member 60. In addition, preferably, the plurality of first protrusions 62 are provided sandwiching the center in the front-rear direction of the end member 60.

[0087] A first storage portion 66 is formed between the first protrusion 62 and the right end portion of the outer surface portion 61. Specifically, as Figure 15A and Figure 15B shown, the first storage portion 66 is a space formed between the first protrusion 62 located on the inner side in the up-down direction of the door of the first mounting surface 55, that is, the inner side of the door 44, and the outer surface portion 61 located on the outer side in the up-down direction of the door of the first mounting surface 55, that is, the outer side of the door 44. The first storage portion 66 is such that the first mounting surface 55 of the door surface member 50 is inserted from the gap 66a formed between the front end portion 62a of the first protrusion 62 and the outer surface portion 61 toward the first end surface portion 52 of the door surface member 50, and the first mounting surface 55 is stored. That is, the above-mentioned gap 66a constitutes the opening portion 66a of the first storage portion 66 for inserting the first mounting surface 55, and the front end portion 62a of the first protrusion 62 forms this opening portion 66a on the inner side of the door 44.

[0088] In Figure 15A and Figure 15B shown, in a state where the first mounting surface 55 of the door surface member 50 is stored in the first storage portion 66, the front end portion 62a of the first protrusion 62 is separated from the first end surface portion 52 of the door surface member 50 in the width direction. That is, as Figure 15B shown, a space S is formed between the front end portion 62a of the first protrusion 62 and the first end surface portion 52 of the door surface member 50. In addition, in this state, the front end portion 62a of the first protrusion 62 is located at least at the height of the front end portion 62a, on the inner side in the width direction with respect to the first protruding portion 55e protruding from the first end surface portion 52 in the width direction.

[0089] As Figure 12 shown, the surface 62c of the first protrusion 62 facing the outer surface portion 61 is preferably inclined toward the inner side in the up-down direction of the door so as to move away from the outer surface portion 61 as it advances from the second inner wall 162 side toward the front end portion 62a. By inclining the surface of the first protrusion 62 facing the outer surface portion 61 in this way, it is easy to insert the first mounting surface 55 into the first storage portion 66.

[0090] As Figure 13As shown, the first protrusion 62 preferably has a first inclined portion 62b provided at its front end portion 62a and inclined inward in the vertical direction of the door so as to move away from the outer surface portion 61 as it advances forward. By providing the first inclined portion 62b on the first protrusion 62, it is easy to insert the first mounting surface 55 into the first storage portion 66. In addition, the first inclined portion 62b can be provided on all of the plurality of first protrusions 62, or the first inclined portion 62b can be provided on a part of the first protrusions 62, such as only on the front-side first protrusion 62.

[0091] As Figure 9A , Figure 9B , Figure 10A , Figure 10B , Figure 14 , Figure 16A , Figure 16B As shown, the end member 60 has a different structure between the end on the left or right side where the first protrusion 62 is provided and the opposite end (for example, the left end).

[0092] Specifically, at the right end of the end member 60, the outer surface portion 61 protrudes toward the right side of the door 44, and a first protrusion 62 is provided facing the outer surface portion 61 and leaving inward in the vertical direction of the door. The first protrusion 62 protrudes less to the right of the door 44 than the outer surface portion 61. That is, the front end portion 62a of the first protrusion 62 is located at a position inside the width direction relative to the right end of the outer surface portion 61. The first protrusion 62 is provided at a part in the front-rear direction at the right end of the end member 60.

[0093] On the other hand, at the left end of the end member 60, the outer surface portion 61 protrudes toward the left side, and a second protrusion 63 is provided facing the outer surface portion 61 and leaving inward in the vertical direction of the door. The second protrusion 63 includes a laterally protruding portion 63a, a laterally grooved inner protruding portion 63b, and a laterally opposed protruding portion 63c, which will be described later, protrudes to the left of the door to the same extent as the outer surface portion 61, and is provided continuously throughout the front-rear direction.

[0094] The laterally protruding portion 63a is a flat plate-shaped protrusion that protrudes from the inner wall 61a1 on the left side of the handle portion 61a toward the outside in the width direction and extends along the front-rear direction. The laterally protruding portion 63a is provided at a certain interval from the left end of the outer surface portion 61, and a second storage portion 67 extending along the front-rear direction is formed between the laterally protruding portion 63a and the left end of the outer surface portion 61.

[0095] The laterally grooved inner protruding portion 63b is a protrusion that protrudes from the laterally protruding portion 63a into the second storage portion 67 toward the outer surface portion 61. The front end of the laterally grooved inner protruding portion 63b is opposed to the outer surface portion 61 at an interval in the vertical direction. In the present embodiment, a plurality of (for example, two) laterally grooved inner protruding portions 63b are provided at intervals in the front-rear direction. As Figure 14 , Figure 16A, Figure 16B As shown in Figure 16B , the second inclined portion 63b1 that is inclined so as to approach the horizontal protrusion 63a as it advances outward in the width direction is provided on the horizontal groove inner protrusion 63b.

[0096] The horizontal opposed protrusion 63c is a plate-shaped protrusion that protrudes inward in the door up-and-down direction from the outer end portion in the width direction of the horizontal protrusion 63a. In the present embodiment, a plurality of horizontal opposed protrusions 63c are provided at intervals in the front-rear direction. Further, the horizontal opposed protrusion 63c is provided on the horizontal protrusion 63a such that the front end portion 63c1 on the outer side in the width direction of the horizontal opposed protrusion 63c and the front end portion 63a1 on the outer side in the width direction of the horizontal protrusion 63a form a flush surface without a step.

[0097] As Figure 16A and Figure 16B shown, the second storage portion 67 formed between the outer surface portion 61 and the horizontal protrusion 63a receives the second mounting surface 58 of the door surface member 50 by inserting the second mounting surface 58. That is, the front end portion 63a1 of the horizontal protrusion 63a forms the second opening portion 67a of the second storage portion 67, and the second mounting surface 58 of the door surface member 50 is inserted into the second storage portion 67 from the second opening portion 67a. The second mounting surface 58 of the door surface member 50 inserted into the second storage portion 67 is guided by the second inclined portion 63b1 and inserted between the horizontal groove inner protrusion 63b and the outer surface portion 61.

[0098] In Figure 14 the state where the second mounting surface 58 of the door surface member 50 is received in the second storage portion 67 as shown, the front end portion 63a1 of the horizontal protrusion 63a and the front end portion 63c1 of the horizontal opposed protrusion 63c face the second end surface portion 56 of the door surface member 50 so as to support the second end surface portion 56. In the present embodiment, the front end portion 63a1 of the horizontal protrusion 63a and the front end portion 63c1 of the horizontal opposed protrusion 63c support the second end surface portion 56 by facing the second end surface portion 56 with a flexible body 69 interposed therebetween. Further, the front end portion 63a1 of the horizontal protrusion 63a and the front end portion 63c1 of the horizontal opposed protrusion 63c may also support the second end surface portion 56 by facing the second end surface portion 56 in a state of direct contact. As the flexible body 69, a member made of a highly flexible material such as polyurethane sponge or rubber called a soft tape, a member formed of resin, paper, cloth, etc. can be used.

[0099] Further, as Figure 16A , Figure 16B shown, the front end portion 63a1 of the horizontal protrusion 63a may also be located at a position inward in the width direction from the left end of the outer surface portion 61 provided on the outer side in the door up-and-down direction of the second storage portion 67.

[0100] As Figure 9A , Figure 9B ,Figure 10A , Figures 11 to 12 , Figure 17 As shown in Figure 17 , the third protrusion 64 is provided with a front protrusion 64a, a front groove inner protrusion 64b, and a front opposed protrusion 64c, and is provided at intervals from the front end portion of the outer surface portion 61 toward the inner side in the vertical direction of the door.

[0101] The front protrusion 64a is a flat plate-shaped protrusion that protrudes forward from the inner side of the door on the front surface of the handle portion 61a and extends along the left-right direction. The front protrusion 64a is provided at a certain interval from the front end portion of the outer surface portion 61, and a groove-shaped third storage portion 68 extending along the left-right direction is formed between the front protrusion 64a and the front end portion of the outer surface portion 61.

[0102] The front groove inner protrusion 64b is a protrusion that protrudes from the front protrusion 64a toward the outer surface portion 61 into the third storage portion 68. The front end of the front groove inner protrusion 64b is opposed to the outer surface portion 61 at intervals in the vertical direction. In the present embodiment, a plurality of front groove inner protrusions 64b are provided at intervals in the left-right direction. As Figure 17 shown in Figure 17 , the front groove inner protrusion 64b is provided with a third inclined portion 64b1 that is inclined so as to approach the front protrusion 64a as it advances forward.

[0103] The front opposed protrusion 64c is a plate-shaped protrusion that protrudes from the front end portion of the front protrusion 64a toward the inner side in the vertical direction of the door. In the present embodiment, a plurality of front opposed protrusions 64c are provided at intervals in the left-right direction. In addition, the front opposed protrusion 64c is provided on the front protrusion 64a such that the front end portion 64c1 on the front side of the front opposed protrusion 64c and the front end portion 64a1 on the front side of the front protrusion 64a form a flush surface without a step.

[0104] As Figure 17 shown in Figure 17 , the third storage portion 68 formed between the outer surface portion 61 and the front protrusion 64a receives the third mounting surface 54 of the door surface member 50 by inserting the third mounting surface 54. That is, the front end portion 64a1 on the front side of the front protrusion 64a forms a third opening portion 68a of the third storage portion 68, and the third mounting surface 54 of the door surface member 50 is inserted into the third storage portion 68 from the third opening portion 68a. The third mounting surface 54 of the door surface member 50 inserted into the third storage portion 68 is guided by the third inclined portion 64b1 and inserted between the front groove inner protrusion 64b and the outer surface portion 61.

[0105] In a state where the third mounting surface 54 of the door front member 50 is stored in the third storage portion 68, the front end portion 64a1 of the front protrusion 64a and the front end portion 64c1 of the front opposing protrusion 64c oppose the front surface portion 51 of the door front member 50 so as to support it. In the present embodiment, the front end portion 64a1 of the front protrusion 64a and the front end portion 64c1 of the front opposing protrusion 64c support the front surface portion 51 by opposing the front surface portion 51 of the door front member 50 with a flexible body 70 that is the same as the flexible body 69. The thickness of the flexible body 70 is preferably thinner than the thickness of the flexible body 69 provided at the front end portion 63a1 of the lateral protrusion 63a and the front end portion 63c1 of the lateral opposing protrusion 63c.

[0106] In addition, the front end portion 64a1 of the front protrusion 64a and the front end portion 64c1 of the front opposing protrusion 64c may also support the second end surface portion 56 of the door front member 50 by opposing it in a state of being in direct contact with the front surface portion 51 of the door front member 50. In addition, the front end portion 64a1 of the front protrusion 64a may be located at a position in front of the front end of the outer surface portion 61 on the outer side in the vertical direction of the door of the third storage portion 68.

[0107] As Figure 10A shown, the left end of the front protrusion 64a that constitutes the third protrusion 64 is connected to the front end of the lateral protrusion 63a that constitutes the second protrusion 63 via a connecting portion 64d, and the third opening of the third storage portion 68 is connected to the front end of the second opening 67a of the second storage portion 67.

[0108] On the other hand, as Figure 10A , Figure 10B and Figure 11 shown, the end of the right end portion of the front protrusion 64a is at a position closer to the inner side in the width direction than the first protrusion 62. In addition, as described above, the front end of the first protrusion 62 provided on the front side is provided behind the third protrusion 64. Therefore, the front end of the first storage portion 66 is provided so as to be rearwardly separated from the right end portion of the third storage portion 68, and the front end of the opening 66a of the first storage portion 66 is provided so as to be separated from the third opening 68a of the third storage portion 68.

[0109] Thus, as Figure 10B shown, in the present embodiment, at the right end portion of the end member 60, the front end portion 62a of the first protrusion 62 is provided so as to be separated from the first end surface portion 52 of the door front member 50 toward the inner side in the width direction. At the left end portion of the end member 60, the second protrusion 63 that supports the second end surface portion 56 of the door front member 50 is provided along the front-rear direction. In addition, at the front end portion of the end member 60, the third protrusion 64 that supports the front surface portion 51 of the door front member 50 is provided along the front-rear direction.

[0110] As Figure 11 and Figure 14As shown, the rear wall 65 is a flat protrusion that protrudes inward from the rear end of the outer surface portion 61 in the vertical direction of the door and extends along the left-right direction. The rear wall 65 is in contact with the surface on the inner side of the door inner panel 100.

[0111] A first covering portion 65a is provided at the right end portion of the rear wall 65, and a second covering portion 65b is provided at the left end portion of the rear wall 65.

[0112] The first covering portion 65a covers, from the rear, the first protruding portion 55e that forms the corner portion at the rear side of the upper right end of the door face member 50 and the first through hole 53a provided at the upper end portion of the first rear face portion 53. A first engaging protrusion 65a1 that protrudes forward is provided on the first covering portion 65a. As Figure 15A and Figure 15B shown, the first engaging protrusion 65a1 is inserted into the first through hole 53a provided in the first rear face portion 53, restricting the movement of the first rear face portion 53 in the width direction.

[0113] As Figure 14 shown, the second covering portion 65b includes an outer covering portion 65b1 that covers, from the rear, the second protruding portion 58e that forms the corner portion at the rear side of the upper left end of the door face member 50, and an inner covering portion 65b2 that covers, from the front, the second through hole 57a provided at the upper end portion of the second rear face portion 57. A second engaging protrusion 65b3 that protrudes rearward is provided on the inner covering portion 65b2. The second engaging protrusion 65b3 is inserted into the second through hole 57a provided in the second rear face portion 57, restricting the movement of the second rear face portion 57 in the width direction.

[0114] As Figure 18 shown, the lower end portion member 75 includes an outer surface portion 76 provided on the outer side of the door 44, a first protrusion 77, a second protrusion 78, and a third protrusion 79 provided on the inner side in the vertical direction of the outer surface portion 76. The outer surface portion 76 has, for example, a shape that bulges downward and forms the bottom of the door 44. The first protrusion 77, the second protrusion 78, and the third protrusion 79 are vertically symmetric with the first protrusion 62, the second protrusion 63, and the third protrusion 64 of the upper end portion member 60, and a first storage portion 80, a second storage portion, and a third storage portion 81 for storing the first mounting surface 55, the second mounting surface 58, and the third mounting surface 54 provided at the lower end portion of the door face member 50 are formed between them and the outer surface portion 76.

[0115] (6) Support member 180

[0116] The support member 180 is a molded product of synthetic resin provided separately from the end portion member 60. As Figure 19A , Figure 19B and Figure 20As shown, the support member 180 is configured to block the front end portion 62a of the first protrusion 62 between the first end face portion 52 of the door face member 50 when being fixed to the end portion member 60 by engaging with the locking claw 163 provided on the end portion member 60, and to support the first end face portion 52.

[0117] More specifically, as Figures 25 to 30 shown, a small wall 166 is formed between the first inner wall 161 and the second inner wall 162 provided on the end portion member 60. The front end of the small wall 166 and the front end of the first inner wall 161 are connected by a connecting wall 166a (refer to Figure 25 ). As described above, two first protrusions 62 are formed on the second inner wall 162. In addition, a locking claw 163 for locking the support member 90 is formed on the first inner wall 161 (refer to Figure 25 ).

[0118] The rear end of the first inner wall 161 is connected to the rear wall 65. In addition, the front end of the second inner wall 162 and the small wall 166 are connected by a connecting wall 162a. Due to such a wall configuration, a region surrounded by the first inner wall 161, the second inner wall 162, the small wall 166, the connecting wall 162a, the connecting wall 166a, and the rear wall 65, that is, an in-wall region, is formed. The support member 180 is fitted in a place including this in-wall region.

[0119] The first inner wall 161 bends twice backward. Therefore, as Figure 25 shown, a front portion 161a extending in the front-rear direction is formed on the first inner wall 161, a rear portion 161b extending in the front-rear direction is formed at the rear, and a bent portion 161c extending in the left-right direction is formed between the front portion 161a and the rear portion 161b. The rear portion 161b is located at a position outside the width direction of the front portion 161a.

[0120] As Figure 25 shown, between the first inner wall 161 and the second inner wall 162, two third inner walls 110a, 110b extending in the front-rear direction, and two fourth inner walls 111a, 111b extending in the left-right direction are formed.

[0121] As Figure 25 shown, the two third inner walls 110a, 110b are formed on the extension line of the small wall 166. The front third inner wall 110a is connected to the small wall 166. On the other hand, the rear third inner wall 110b is connected to the bent portion 161c of the first inner wall 161. The front third inner wall 110a and the rear third inner wall 110b are not connected.

[0122] As Figure 25As shown, the rear end of the front third inner wall 110a and the second inner wall 162 are connected by the front fourth inner wall 111a. Further, the front end of the rear third inner wall 110b and the second inner wall 162 are connected by the rear fourth inner wall 111b.

[0123] Here, the second inner wall 162, the connecting wall 162a, the third inner walls 110a and 110b, and the fourth inner walls 111a and 111b are lower than the first inner wall 161, the small wall 166, and the connecting wall 166a. That is, they are shorter in the vertical direction.

[0124] The above-mentioned wall inner region is divided into three small intervals by the two third inner walls 110a and 110b and the two fourth inner walls 111a and 111b. The three small intervals are the small interval 160a on the side of the first inner wall 161, the small interval 160b divided from the small interval 160a by the front third inner wall 110a and the fourth inner wall 111a, and the small interval 160c divided from the small interval 160a by the rear third inner wall 110b and the fourth inner wall 111b.

[0125] As Figure 26 and Figure 27 shown, the support member 180 has a first end face 182 on the inner side in the width direction (the side of the first inner wall 161) and a second end face 183 on the outer side in the width direction (the side of the first end face portion 52 of the facade member 50). Moreover, as Figure 26 shown, a first groove 184a extending in the front-rear direction is formed between the first end face 182 and the second end face 183. Further, notches 185 extending toward the second end face 183 are formed respectively from two positions in the front-rear direction of the first groove 184a.

[0126] Moreover, in the support member 180, there are formed: a second groove 184b extending in the front-rear direction at a position in front and closer to the inner side in the width direction (the side of the first inner wall 161) than the first groove 184a, a third groove 184c extending in the front-rear direction at a position behind the second groove 184b and on the extension line of the second groove 184b, a fourth groove 184d extending in the left-right direction and connecting the front end of the first groove 184a and the second groove 184b, a fifth groove 184e extending in the left-right direction and connecting the rear end of the second groove 184b and the first groove 184a, and a sixth groove 184f extending in the left-right direction and connecting the front end of the third groove 184c and the first groove 184a.

[0127] Further, in the support member 180, a convex portion 187 that protrudes upward from the first groove 184a and the fourth groove 184d and avoids the notches 185 is formed between the first groove 184a and the fourth groove 184d and the second end face 183.

[0128] When the support member 180 is fitted to the end member 60, it is locked by the locking claw 163 and fixed to the end member 60, and each inner wall of the end member 60 enters the grooves formed in the support member 180. Specifically, the second inner wall 162 enters the first groove 184a, the small wall 166 and the front third inner wall 110a enter the second groove 184b, the rear third inner wall 110b enters the third groove 184c, the connecting wall 162a enters the fourth groove 184d, the front fourth inner wall 111a enters the fifth groove 184e, and the rear fourth inner wall 111b enters the sixth groove 184f. In addition, the first protrusion 62 enters the notch 185.

[0129] As Figure 29 shown, a first sealing portion 178 that prevents the foamed heat insulating material in a fluid state from passing through is formed between the first end face 182 of the support member 180 and the first inner wall 161 of the end member 60. In addition, a second sealing portion 179 that prevents the heat insulating material in a fluid state from passing through is formed between at least one side wall surface of the first groove 184a of the support member 180 and the second inner wall 162 of the end member 60.

[0130] Moreover, a sealing portion that prevents the heat insulating material from moving in the left - right direction is also formed between the side wall surface of the third groove 184c in the support member 180 and the rear third inner wall 110b in the end member 60 (refer to Figure 29 ). In addition, a sealing portion that prevents the heat insulating material from moving in the left - right direction is also formed between the side wall surface of the second groove 184b in the support member 180 and the front third inner wall 110a in the end member 60.

[0131] In addition, a sealing portion that prevents the heat insulating material from moving in the front - rear direction is formed between the side wall surface of the fifth groove 184e in the support member 180 and the front fourth inner wall 111a in the end member 60. In addition, a sealing portion that prevents the heat insulating material from moving in the front - rear direction is also formed between the side wall surface of the sixth groove 184f in the support member 180 and the rear fourth inner wall 111b in the end member 60.

[0132] In any of the sealing portions, there may be a minute gap (for example, 0.5 mm or less) between the two surfaces, or the two surfaces may be in contact. In addition, it is preferable to provide a flexible body same as the above - mentioned flexible body 69 in the sealing portion so that the foamed heat insulating material in a fluid state cannot pass from one end to the other end of each sealing portion.

[0133] When filling the space defined by the door panel member 50, the inner door panel 100, and the upper and lower end members 60 and 75 with the foamed heat insulating material, this support member 180 suppresses the positional deviation of the first end face portion 52 or suppresses the outflow of the foamed heat insulating material to the outside from the front end portion 62a of the first protrusion 62 or the gap between the second inner wall 162 and the first mounting surface 55.

[0134] That is, inside the inner wall region between the first inner wall 161 and the second inner wall 162, the movement of the heat insulating material is also blocked, so the heat insulating material is not likely to leak outside the door 44. In addition, as described above, the inner wall region is divided into three small sections 160a, 160b, and 160c. Therefore, even if the heat insulating material accidentally enters one of the small sections, it is not likely to enter other small sections. In view of this, the heat insulating material is also not likely to leak outside the door 44.

[0135] The convex portion 187 provided on the support member 180 faces the first mounting surface 55 in a directly contacting state or is opposed to each other with a flexible body same as the flexible body 69 interposed therebetween, and clamps the first mounting surface 55 between the outer surface portion 61.

[0136] The second end face 183 of the support member 180 faces the first end face portion 52 in a directly contacting state or is opposed to each other with a flexible body 91 same as the flexible body 69 interposed therebetween as shown, and supports the first end face portion 52. Figure 20 shown, and supports the first end face portion 52.

[0137] In addition, in the lower end member 75, a region surrounded by an inner wall, a second inner wall, a small wall, a connecting wall, a connecting wall, and a rear wall (not shown), that is, an inner wall region, is formed in the same manner as the inner wall region formed in the upper end member 60. However, since it has a structure that is vertically symmetric with the inner wall region of the upper end member 60, the support member attached to the lower end member 75 and the support member 180 attached to the upper end member 60 described above have vertically symmetric shapes.

[0138] (7) Manufacturing method of the door 44

[0139] Next, the manufacturing method of the above-mentioned door 44 will be described. In the manufacturing process of the door 44, first, an operator assembles the upper end member 60, the lower end member 75, the door panel member 50, the upper support member 180, and the lower support member.

[0140] Specifically, first, the operator attaches the upper end member 60 to the door panel member 50. In detail, as indicated by the arrow in (a) of Figure 21 the operator slides the end member 60 to the left at the upper end of the door panel member 50 and inserts the second mounting surface 58 of the door panel member 50 into the second receiving portion 67 located on the left side of the end member 60.

[0141] Next, as indicated by the arrow in (b) of Figure 21 , while maintaining the state where the rear end portion of the second mounting surface 58 of the facade member 50 is inserted into the second storage portion 67, the operator moves the right side portion of the end member 60 rearward relative to the facade member 50, resulting in a state where the rear end portion of the second mounting surface 58 of the facade member 50 is inserted into the second storage portion 67 of the end member 60, and the front end portion of the second mounting surface 58 is separated from the second opening portion 67a of the second storage portion 67 toward the inner side in the width direction. In this state, the right side portion of the end member 60 is located at a position rearward of the facade member 50.

[0142] Next, as indicated by the arrow in (c) of Figure 21 , the operator rotates the end member 60 about the rear side of the second opening portion 67a so that the front end portion of the second mounting surface 58 is inserted into the second opening portion 67a of the second storage portion 67.

[0143] Thereby, the third mounting surface 54 of the facade member 50 is inserted into the third storage portion 68 from the left end portion. In addition, the end member 60 is provided such that the front end of the first storage portion 66 is separated rearward from the right end portion of the third storage portion 68, and the front end of the opening portion 66a of the first storage portion 66 is separated from the third opening portion 68a of the third storage portion 68. Therefore, even if the operator rotates the end member 60 as described above, the third protrusion 64 forming the third storage portion 68 is not likely to interfere with the first protrusion 55e provided on the facade member 50 (refer to Figure 22 ).

[0144] Then, as shown in (d) of Figure 21 , when the operator further rotates the end member 60, the first protrusion 62 forming the first storage portion 66 passes through the inner side in the width direction of the first protrusion 55e. In the present embodiment, the front end portion 62a of the first protrusion 62 is located at a position on the inner side in the width direction of the first protrusion 55e provided on the facade member 50, and the rotation locus of the front end portion 62a of the first protrusion 62 is located at a position on the inner side in the width direction of the first protrusion 55e of the facade member 50. Therefore, when the first protrusion 62 passes through the inner side in the width direction of the first protrusion 55e, the first protrusion 62 is not likely to interfere with the first protrusion 55e (refer to Figure 23 ).

[0145] Then, when the operator further rotates the end member 60, the first mounting surface 55 is inserted into the first storage portion 66 formed between the first protrusion 62 and the outer surface portion 61 of the end member 60 (refer to Figure 24)。In this embodiment, the protruding amount of the rear end portion 55b of the first mounting surface 55 from the first end surface portion 52 is smaller than that of the central portion 55c. Therefore, the first mounting surface 55 can be easily inserted into the first receiving portion 66.

[0146] Then, as shown in (e) of Figure 21 , when the operator further rotates the end portion member 60 and the front end portion of the second mounting surface 58 is inserted into the second receiving portion 67 from the second opening portion 67a, the entire third mounting surface 54 is inserted into the third receiving portion 68, and the first mounting surface 55 is inserted into the first receiving portion 66. In addition, the first engaging protrusion 65a1 provided on the rear wall 65 of the end portion member 60 is inserted into the first through hole 53a provided on the first rear surface portion 53, and the second engaging protrusion 65b3 is inserted into the second through hole 57a provided on the second rear surface portion 57. Thus, the installation of the upper end portion member 60 to the door surface member 50 is completed.

[0147] Since the front end portion 62a of the first protrusion 62 is separated from the first end surface portion 52, when the end portion member 60 is installed on the door surface member 50 according to the steps of (b) to (e) of Figure 22 , a certain amount of looseness is generated between the upper end portion member 60 and the door surface member 50.

[0148] Therefore, after the operator installs the upper end portion member 60 on the door surface member 50, the support member 180 is embedded in the above-mentioned wall inner region formed between the first inner wall 161 and the second inner wall 162 of the end portion member 60 (refer to Figure 19A ). When the support member 180 is embedded in the wall inner region, it is engaged with the locking claw 163 and fixed to the end portion member 60 (refer to Figure 19B ). Thus, it is arranged to block the space between the front end portion 62a of the first protrusion 62 and the first end surface portion 52 of the door surface member 50, support the first end surface portion 52, and prevent the foamed heat insulating material from flowing out to the outside through the gap between the front end portion 62a of the first protrusion 62 and the gap between the second inner wall 162 and the first mounting surface 55.

[0149] In addition, the operator installs the lower end portion member 75 on the door surface member 50 according to the same steps as those of the upper end portion member 60, and installs the support member 180 at a specified position. Thus, the door 44 becomes an assembled state, and a space with an open back is formed by the door surface member 50, the end portion members 60, and 75.

[0150] After being assembled in this way, the operator injects a fluid foaming resin stock solution such as polyurethane foam into the inner space of the door 44 through the opening at the back, and then installs the inner door panel 100 on the upper and lower end members 60 and 75 and the first rear surface portion 53 and the second rear surface portion 57 of the door front member 50. The foaming resin stock solution expands by foaming and flows in the inner space of the door 44, and cures after filling the inner space of the door 44, and the door 44 is completed.

[0151] The operator also manufactures other doors through the same process as the small refrigerating chamber door 44. Then, the operator installs the completed respective doors and various devices on the outer shell 11, and the refrigerator 10 is completed.

[0152] (8) Effects

[0153] In the present embodiment, the front end portion 62a of the first protrusion 62 of the end member 60 is provided so as to be separated from the first end surface portion 52 of the door front member 50. Therefore, by rotating the end member 60 as described above, the end member 60 can be installed on the door front member 50 while suppressing deformation of the door front member 50.

[0154] In the present embodiment, the front end portion 62a of the first protrusion 62 is located at a position inside the width direction of the first protrusion 55e of the door front member 50. Therefore, when the end member 60 is rotated as described above and the end member 60 is installed on the door front member 50, the first protrusion 62 is not likely to interfere with the first protrusion 55e, and the end member 60 can be installed on the door front member 50 while suppressing deformation of the door front member 50.

[0155] In the present embodiment, the support member 180 provided separately from the end member 60 blocks the space between the front end portion 62a of the first protrusion 62 and the first end surface portion 52 while supporting the first end surface portion 52. Therefore, even if the front end portion 62a of the first protrusion 62 is separated from the first end surface portion 52 of the door front member 50, it is possible to suppress the outflow of the foamed heat insulating material as described above, and it is possible to suppress the floating phenomenon in the first end surface portion 52.

[0156] And, in the present embodiment, the support member 180 is provided at the right end portion of the door 44 where the recess of the handle portion 61a is small. Therefore, when the support member 180 is installed on the end member 60, the handle portion 61a is not likely to be an obstacle, and the workability is relatively good.

[0157] In addition, in the present embodiment, the second protrusion 63 supports the second end surface portion 56, so that the floating phenomenon in the second end surface portion 56 can be suppressed.

[0158] In the present embodiment, as described above, the front end of the opening 66a of the first storage portion 66 is provided so as to be separated from the third opening 68a of the third storage portion 68. Therefore, even if the operator rotates the end member 60 as described above to install the door face member 50, the third protrusion 64 forming the third storage portion 68 is not likely to interfere with the first protrusion 55e provided on the door face member 50. Therefore, the end member 60 can be installed on the door face member 50 while suppressing deformation of the door face member 50.

[0159] In the present embodiment, a plurality of openings 66a of the first storage portion 66 are provided at intervals in the front-rear direction. Therefore, it is easy to sandwich the first mounting surface 55 between the support member 180 and the outer surface portion 61, and the floating phenomenon in the first end face portion 52 can be suppressed. Further, as in the present embodiment, when the plurality of first protrusions 62 forming the opening 66a of the first storage portion 66 are provided on both the front and rear sides of the end member 60 with the center in the front-rear direction of the end member 60 interposed therebetween, the first mounting surface 55 of the door face member 50 can be supported well in the front-rear direction.

[0160] Further, in the present embodiment, when the amount of protrusion of the rear end portion 55b of the first mounting surface 55 of the door face member 50 from the first end face portion 52 is smaller than that of the central portion 55c of the first mounting surface 55, when the operator rotates the end member 60 as described above to install the door face member 50, the first mounting surface 55 is not likely to interfere with the end member 60, and the end member 60 can be installed on the door face member 50 while suppressing deformation of the door face member 50.

[0161] Further, when the first protrusion 62 is provided with a first inclined portion 62b that inclines inward in the door up-down direction so as to be separated from the outer surface portion 61 as it advances toward the front end at the front end portion 62a, it is easy to insert the first mounting surface 55 into the first storage portion 66.

[0162] Further, in the present embodiment, when the thickness of the flexible body 70 provided at the front end portion 64a1 of the front protrusion 64a and the front end portion 64c1 of the front opposed protrusion 64c is thinner than the thickness of the flexible body 69 provided at the front end portion 63a1 of the lateral protrusion 63a and the front end portion 63c1 of the lateral opposed protrusion 63c, it is possible to improve the workability of installing the end member 60 on the door face member 50 and the shape formability of the front face portion 51 of the door face member 50.

[0163] That is, by providing the flexible bodies 69 provided at the front end portions 63a1 of the horizontal protrusions 63a and the front end portions 63c1 of the horizontally opposed protrusions 63c with thickness, when the operator rotates the end member 60 as described above to install the door face member 50, the elastic deformation of the flexible bodies 69 causes the end member 60 to move toward the second end face portion 56 of the door face member 50. Thus, the first protrusion 62 is less likely to interfere with the door face member 50, and it is easy to install the end member 60. In addition, by making the thickness of the flexible body 70 provided at the front end portion 64a1 of the front protrusion 64a and the front end portion 64c1 of the front opposed protrusion 64c thinner than the thickness of the flexible body 69, even if the front face portion 51 is a gentle curved shape or the like in which the front face portion 51 of the door face member 50 changes in the front-back position in the left-right direction, i.e., a shape other than a plane, it is easy to form the front face portion 51 into a desired shape along the front end portion 64a1 of the front protrusion 64a and the front end portion 64c1 of the front opposed protrusion 64c.

[0164] In addition, in the present embodiment, the front end portion 63a1 of the horizontal protrusion 63a is positioned on the inner side in the width direction with respect to the left end of the outer face portion 61 provided outside the upper and lower directions of the door in the second storage portion 67. Thus, it is easy to ensure the thickness of the flexible body 69 provided between the front end portion 63a1 of the horizontal protrusion 63a and the second end face portion 56 of the door face member 50, and it is easy to install the end member 60 on the door face member 50.

[0165] In addition, in the present embodiment, the front end portion 64a1 of the front protrusion 64a is positioned in front of the front end of the outer face portion 61 provided outside the upper and lower directions of the door in the third storage portion 68. Thus, it is possible to support the front face portion 51 while suppressing the thickness of the flexible body 70 provided between the front end portion 64a1 of the front protrusion 64a and the front end portion 64c1 of the front opposed protrusion 64c and the front face portion 51 of the door face member 50. Therefore, even if the front face portion 51 is a gentle curved shape or the like in which the front face portion 51 of the door face member 50 changes in the front-back position in the left-right direction, i.e., a shape other than a plane, it is easy to keep the front face portion 51 in a desired shape along the front end portion 64a1 of the front protrusion 64a and the front end portion 64c1 of the front opposed protrusion 64c.

[0166] (9) Modification example

[0167] As described above, the embodiments of the present invention have been described, but these embodiments are presented as examples and are not intended to limit the scope of the invention. These embodiments can be implemented in various other ways, and various omissions, substitutions, and changes can be made without departing from the gist of the invention. These embodiments and their modifications are included in the scope and gist of the invention, and are included in the invention described in the claims and its equivalent scope.

[0168] For the above-described embodiments, any one of the multiple modification examples described below can be applied, or any two or more of the modification examples described below can be combined and applied. In addition, various modifications can be made other than the following modification examples.

[0169] (10) Modification Example 1

[0170] In the above-described embodiment, a first protrusion 62 that is separated from the first end face portion 52 of the door face member 50 toward the inner side in the width direction is provided at the right end portion of the end member 60, and a second protrusion 63 that supports the second end face portion 56 of the door face member 50 is provided at the left end portion of the end member 60. However, for example, as Figure 25 shown, a protrusion 112 that is the same as the first protrusion 62 provided at the right end portion of the end member 60 is provided at the left end portion of the end member 60. That is, a protrusion 112 whose front end portion 112a is separated from the second end face portion 56 of the door face member 50 toward the inner side in the width direction is provided at the left end portion of the end member 60. Then, in the above-described embodiment, a support member (not shown) that is the same as the support member 180 installed at the right end portion of the end member 60 can also be fixed to the end member 60, and while blocking between the front end portion of this protrusion and the second end face portion 56 of the door face member 50, the second end face portion 56 is supported.

[0171] Or, as Figure 26 shown, at the left end portion of the end member 60, a protrusion for forming a storage portion for storing the second mounting surface 58 of the door face member 50 is not provided, and a support member (not shown) that is the same as the support member 180 installed at the right end portion of the end member 60 in the above-described embodiment is fixed to the end member 60, and while blocking between the second end face portion 56 of the door face member 50 and the end member 60, the second end face portion 56 is supported.

[0172] In this modification example, when the end member 60 is installed on the door face member 50, the first mounting surface 55 can be inserted into the first storage portion 66 and temporarily fixed, so the workability of assembling the door 44 is relatively good.

[0173] (11) Modification Example 2

[0174] In the above-described embodiment, one side in the width direction of the handle portion 61a is set as a gentler inclined surface than the other side, so that the handle portion 61a has a shape with less depression on one side in the width direction. However, the handle portion 61a can also be set to be biased toward one side in the width direction of the door 44, and the other side can be made into a shape with less depression.

[0175] (12) Modification Example 3

[0176] In the above description, the support member 180 is provided at the right end of the end member 60 provided on the small refrigerating chamber door 44, but the first protrusion 62 and the support member 180 may also be provided at the left end. In addition, regarding the left and right refrigerating chamber doors 40, 41, the vegetable chamber door 42, the ice making chamber door 43, and the refrigerating chamber door 45 other than the small refrigerating chamber door 44, the same end member 60 as that of the door 44 can be installed on the door surface member 50, and the end of the end member 60 provided with the first protrusion 62 can be installed on the door surface member 50 through the support member 180.

[0177] When the end member 60 is installed on the door surface member by using the support member in the doors 40, 41, 42, 43, 44, 45 provided in the refrigerator, the first protrusion 62 and the support member can be provided at any end in the left-right direction of the end member 60.

[0178] For example, in a refrigerator in which a pair of left and right refrigerating chamber doors 40, 41 are provided at the front opening of the refrigerating chamber 20, when the support members 180A, 180B, 180C, 180D, and 180E are used to fix the upper and lower end members provided on the doors 40, 41, 42, 43, 44, 45, the support members 180A, 180B, 180C, 180D, and 180E can be provided as Figure 33 shown. In addition, the support members 180A, 180B, 180C, 180D, and 180E all have a basic configuration common to the above support member 180, but the shape of the support member 180 varies depending on the position, size, shape, etc. of the handle portion provided on the door and the position where the support member is provided.

[0179] That is, in a refrigerator in which a pair of left and right refrigerating chamber doors 40, 41 are provided at the front opening of the refrigerating chamber 20, when fixing the lower end members 60 of the refrigerating chamber doors 40, 41, it is preferable to provide the support members 180A, 180B at the ends on the central side in the width direction of the refrigerator (i.e., the side opposite to the hinge).

[0180] The refrigerating chamber doors 40, 41 are narrower in width than the vegetable chamber door 42 and the refrigerating chamber door 45, and there is a hinge structure for rotatably supporting the refrigerating chamber doors 40, 41 on the outer side in the width direction of the refrigerator. Therefore, it is not easy to ensure a space for installing the support members 180A, 180B inside the door. However, by providing the support members 180A, 180B on the central side in the width direction of the refrigerator, it is easy to ensure a space for installing the support members 180A, 180B inside the door. In addition, the support member 180A provided on the left refrigerating chamber door 40 and the support member 180B provided on the right refrigerator door 41 have a left-right symmetric shape.

[0181] When fixing the end parts 60 on the upper sides of the refrigerator compartment doors 40 and 41, support parts 180D and 180E with different shapes are respectively provided at the end parts on the outer side in the width direction of the refrigerator (i.e., the hinge side).

[0182] When fixing the end part 60 on the upper side of the ice-making compartment door 43, it is only necessary to provide a support part 180B at the end part on the central side in the width direction of the refrigerator. The support part 180B for fixing the end part on the lower side of the above-mentioned right refrigerator compartment door 41 is provided at the corner part sandwiched by the lower side and the left side of the refrigerator compartment door 41. When the corner part of the refrigerator compartment door 41 rotates and moves in a way that the upper and lower parts are replaced, it becomes a shape common to the corner part sandwiched by the upper side and the right side of the ice-making compartment door 43. Therefore, as the support part for fixing the end part 60 on the upper side of the ice-making compartment door 43, by using a part with the same shape as the support part 180B for fixing the end part 60 on the lower side of the right refrigerator compartment door 41, it is possible to reduce the number of parts and thus suppress the manufacturing cost.

[0183] When fixing the end part 60 on the lower side of the ice-making compartment door 43, it is only necessary to provide a support part 180A at the end part on the central side in the width direction of the refrigerator. Both the refrigerator compartment door 40 and the ice-making compartment door 43 are narrow in the left-right direction, and there is a commonality in the arrangement of the corner part sandwiched by the lower side and the right side of the ice-making compartment door 43 and the corner part sandwiched by the lower side and the right side of the refrigerator compartment door 40. Therefore, by providing the support part for fixing the end part 60 on the lower side of the ice-making compartment door 43 at the end part on the central side in the width direction of the refrigerator, it is possible to use a support part with the same shape as the support part 180A for fixing the end part 60 on the lower side of the refrigerator compartment door 40, and thus suppress the manufacturing cost.

[0184] When fixing the end part 60 on the upper side of the small refrigerating compartment door 44, it is only necessary to provide a support part 180A at the end part on the central side in the width direction of the refrigerator. Similar to the above, the support part 180A for fixing the end part 60 on the upper side of the small refrigerating compartment door 44 can use a support part with the same shape as the support part 180A for fixing the end part on the lower side of the left refrigerator compartment door 41 and the support part 180A for fixing the end part 60 on the lower side of the ice-making compartment door 43.

[0185] When fixing the end part 60 of the lower side of the small refrigerating chamber door 44, it is only necessary to provide a support member 180B at the end on the central side in the width direction of the refrigerator. Similarly, the support member 180B for fixing the end part 60 of the lower side of the small refrigerating chamber door 44 can be a support member having the same shape as the support member 180B for fixing the end part of the lower side of the right refrigerating chamber door 41 and the support member 180B for fixing the end part 60 of the upper side of the ice-making chamber door 43.

[0186] In addition, when fixing the end parts 60 of the upper sides of the vegetable chamber door 42 and the refrigerating chamber door 45, which are doors provided across the entire width of the refrigerator, a support member 180C is provided at the end on either the left or right side (the left side in Figure 33 this case). When fixing the end parts 60 of the lower sides of the vegetable chamber door 42 and the refrigerating chamber door 45, a support member 180C is provided at the end on the other side (the right side in Figure 33 this case).

[0187] By arranging the support member 180C in this way, the end part 60 can be fixed by one type of support member 180C in the doors provided across the entire width of the refrigerator.

[0188] (13) Modification Example 4

[0189] In addition, in a refrigerator in which one refrigerating chamber door 140 is provided in the refrigerating chamber 20 as shown in Figure 34 , when fixing the end parts provided on the upper and lower sides of the doors 140, 142, 143, 144, and 145 using the support members 180a, 180b, 180c, and 180d, the support members 180a, 180b, 180c, and 180d can be arranged as shown in Figure 34 . In addition, the support members 180a, 180b, 180c, and 180d all have a basic configuration common to the above support member 180, but the shape of the support member 180 varies depending on the position, size, shape, etc. of the handle part provided on the door and the position where the support member is provided.

[0190] When fixing the end part 60 on the upper side of the refrigerating chamber door 140, support members 180c and 180d with different shapes are respectively provided at both end parts in the width direction. In addition, when fixing the end part 60 on the lower side of the refrigerating chamber door 140, support members 180a and 180b with different shapes are respectively provided at both end parts in the width direction. Although the support member 180c on the left side of the end part 60 on the upper side of the refrigerating chamber door 140 and the support member 180b on the right side of the end part 60 on the lower side of the refrigerating chamber door 140 can be made into members with the same shape, since a handle is provided on the end part 60 on the lower side of the refrigerating chamber door 140 and no handle is provided on the end part 60 on the upper side of the refrigerating chamber door 140, in the end part 60 on the lower side of the refrigerating chamber door 140, there are greater spatial restrictions when providing support members at the end, so in this modification example, different-shaped members are used for the support member 180c on the left side of the end part 60 on the upper side of the refrigerating chamber door 140 and the support member 180b on the right side of the end part 60 on the lower side of the refrigerating chamber door 140. Similarly, although the support member 180d on the right side of the end part 60 on the upper side of the refrigerating chamber door 140 and the support member 180a on the left side of the end part 60 on the lower side of the refrigerating chamber door 140 can be made into members with the same shape, different-shaped members are used in this modification example.

[0191] When fixing the end parts 60 on the upper and lower sides of the vegetable chamber door 142, ice making chamber door 143, small refrigerating chamber door 144, and refrigerating chamber door 145, which are pull-out doors, support members 180a and 180b can be provided at the outer end parts in the width direction of the refrigerator.

[0192] For example, in the vegetable chamber door 142 and the refrigerating chamber door 145, which are doors provided across the entire width of the refrigerator, support members 180a and 180b are provided at the end part on either the left or right (left side in Figure 34 ), and in the ice making chamber door 143 and the small refrigerating chamber door 144, which are doors with two doors arranged side by side in the width direction of the refrigerator, a support member is provided at the left end in the ice making chamber door 143 on the left side, and a support member is provided at the right end in the ice making chamber door 143 on the right side.

[0193] When fixing the end part 60 on the upper side of the vegetable chamber door 142, ice making chamber door 143, and refrigerating chamber door 145 at the left end, a support member 180b with the same shape as the support member 180b for fixing the end part 60 on the lower side of the refrigerating chamber door 140 at the right end can be used.

[0194] When fixing the end part 60 at the lower side of the vegetable compartment door 142, the ice making compartment door 143, and the refrigerating compartment door 145 at the left end, the support member 180a having the same shape as the support member 180a for fixing the end part 60 at the lower side of the refrigerating compartment door 140 at the left end can be used.

[0195] In addition, when fixing the end part 60 at the upper side of the small refrigerating compartment door 144 at the right end, the support member 180a having the same shape as the support member 180a for fixing the end part 60 at the lower side of the refrigerating compartment door 140 at the left end can be used.

[0196] When fixing the end part 60 at the lower side of the small refrigerating compartment door 144 at the right end, the support member 180b having the same shape as the support member 180b for fixing the end part 60 at the lower side of the refrigerating compartment door 140 at the right end can be used.

Claims

1. A refrigerator comprising a refrigerator body having a storage chamber therein, and a door provided on the refrigerator body, wherein: The door includes a door surface member forming a front surface of the outer side of the box, and an end member attached to an end of the door surface member. The door surface member includes a first end surface protruding rearward from a first end edge of the front surface, and a first mounting surface protruding inward in the width direction from an upper side or a lower side of the first end surface. The end member has an opening into which the first mounting surface is inserted, A front end portion forming the opening portion on the inner side of the door is provided away from the first end surface toward the inner side in the width direction.

2. The refrigerator according to claim 1, wherein: The facade component has: a rear surface protruding inward in the width direction from a rear end edge of the first end surface; and a protrusion, connecting the rear portion of the first mounting surface to the rear surface, and protruding from the first end surface inward in the width direction, The front end portion is located on the inner side in the width direction of the protruding portion.

3. The refrigerator according to claim 1, wherein: A support member is provided separately from the end member, and the support member is provided so as to block a space between the front end portion and the first end surface and support the first end surface.

4. The refrigerator according to claim 3, wherein: The end member includes a handle portion that is recessed toward the inner side of the door to form a handle. The handle portion has a shape in which one end side in the width direction of the door is less recessed toward the inner side of the door than the other end side, and the support member is provided on the one end side.

5. The refrigerator according to claim 1, wherein: The door surface member includes a second end surface protruding rearward from a second end side facing the first end side in the front surface, and a second mounting surface protruding inward in the width direction from a side of an upper side or a lower side of the second end surface on which the end member is mounted. The end member includes a second opening for inserting the second mounting surface. A front end portion forming the second opening portion on the inner side of the door is provided to support the second end surface.

6. The refrigerator according to claim 1, wherein: The door surface member includes a second end surface protruding rearward from a second end side facing the first end side in the front surface. A support member that supports the second end surface is provided separately from the end member.

7. The refrigerator according to claim 1, wherein: The door surface member includes a third mounting surface that protrudes rearward from the side of the upper side or the lower side of the front surface on which the end member is mounted and is inserted into the end member. The end member includes a third opening into which the third mounting surface is inserted. The front end of the opening portion into which the first mounting surface is inserted is disposed away from the third opening portion.

8. The refrigerator according to claim 1, wherein: The rear end of the opening into which the first mounting surface is inserted is disposed away from the rear end of the end member forward.

9. The refrigerator according to claim 1, wherein: The opening portion into which the first mounting surface is inserted is provided at a plurality of locations in the front-rear direction.

10. The refrigerator according to claim 1, wherein: The front end portion forming the opening portion into which the first mounting surface is inserted includes an inclined portion inclined so as to be separated from the first mounting surface toward the front end.

11. The refrigerator according to claim 1, wherein: The door surface member includes a rear surface protruding from a rear end edge of the first end surface toward the inside in the width direction, and a through hole penetrating the rear surface in the front-rear direction. The end member includes a protrusion that is inserted into the through hole from the rear.

12. The refrigerator according to claim 2, wherein: The door surface member includes a second end surface protruding rearward from a second end side facing the first end side in the front surface, and a second mounting surface protruding inward in the width direction from a side of an upper side or a lower side of the second end surface on which the end member is mounted. The end member includes a second opening portion into which the second mounting surface is inserted, When the end part is installed to the door component, the rear end of the second mounting surface is inserted into the second opening, and the end part is rotated around the rear side of the second opening from a state in which the front end of the second mounting surface leaves the second opening so that the rotation trajectory of the front end when the front end of the second mounting surface is inserted into the second opening is located at a position closer to the inside in the width direction than the protrusion of the door component.

13. A method for manufacturing a refrigerator door, the refrigerator door comprising a door face member forming a front surface of an outer side of the refrigerator, and an end member mounted on an end of the door face member, wherein: The door surface component comprises: a first end surface, which protrudes backward from a first end edge of the front surface; a second end surface, which protrudes backward from a second end edge facing the first end edge in the front surface; a first mounting surface, which protrudes inward in the width direction from an upper edge or a lower edge of the first end surface; and a second mounting surface, which protrudes inward in the width direction from a side of an upper edge or a lower edge of the second end surface on which the end component is mounted. The end member includes an opening portion at one end side in the width direction, the opening portion being opened so that the first mounting surface can be inserted therein. The method for manufacturing the refrigerator door comprises: a step of inserting a rear end portion of the second mounting surface into the other end side of the end member opposite to the one end side and setting the front end portion of the second mounting surface to a state away from the other end side of the end member; as well as The step of rotating the end member about the rear side of the other end of the end member, inserting the front end of the second mounting surface into the other end of the end member, and inserting the first mounting surface into the opening of the end member.

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