Split type refrigerator and manufacturing method thereof

Abstract

The application discloses a split type refrigerator and a manufacturing method thereof. The manufacturing method sets a general refrigeration main machine and a standard connection interface, designs a box body assembly according to a target capacity, and splits the box body assembly into a frame assembly, a plate and a functional assembly. At least part of the same name frame pieces in the box body assembly of different capacity specifications adopt the same cross-section structure, different capacity specifications are formed by changing the length of the frame pieces, and the frame pieces are manufactured by using the same extrusion die. The plate can be formed by extrusion, sheet metal or plastic suction, and the functional assembly can be manufactured by using a general mold frame and replaceable insert injection molding. After being connected, fastened and sealed, the box body assembly is connected with the general refrigeration main machine to form the split type refrigerator. The application can improve the part and mold universality between different capacity models, reduce the investment of large molds and the cost of model expansion, and is beneficial to the split transportation, lightweight and maintenance and replacement of the box body.

Description

Technical Field

[0001] This invention relates to the field of refrigeration equipment manufacturing technology, and in particular to a split-type refrigerator and its manufacturing method. Background Technology

[0002] Portable compressor refrigerators typically consist of a refrigeration unit and an insulated cabinet to create storage space. Existing products often use rotational molding, injection molding, vacuum forming, or integral foaming to manufacture the outer shell and inner liner, with corresponding structures and molds designed for different capacity models.

[0003] Among them, rotational molding typically uses a one-piece polyethylene shell with an internal polyurethane foam insulation layer, resulting in high overall structural strength. However, large rotational molding molds are expensive and have long molding cycles. Injection molding usually involves separately injection molding the inner liner and outer shell, followed by foam filling. When the structure changes between different models, it is often necessary to re-mold. Although vacuum forming has relatively low mold costs, it still requires corresponding tooling for inner liners or outer shells of different sizes. The overall foaming solution requires a large foaming mold and more complex assembly and injection processes.

[0004] For product series with multiple capacity specifications, if each capacity model uses an independent cabinet structure and independent mold, it is difficult to share parts and molds between different models. This not only increases the costs of mold investment, supply chain management, and inventory management, but also prolongs the development cycle of new capacity models. At the same time, the cabinet after one-piece rotational molding or integral foaming is usually difficult to disassemble, and the internal space of the cabinet cannot be effectively compressed during the transportation of the whole machine, resulting in a large packaging and logistics volume.

[0005] Furthermore, when the refrigeration unit, cabinet panels, or partial functional components are damaged, the integrated cabinet usually requires extensive disassembly or even complete replacement, resulting in poor maintenance convenience. Therefore, it is necessary to redesign the product structure and manufacturing system of portable compressor refrigerators to allow different capacity models to share more of the main unit, structural components, and molding molds, while also considering lightweight cabinets, ease of disassembly and transportation, and convenient maintenance. Summary of the Invention

[0006] The present invention aims to at least solve one of the technical problems existing in the prior art. To this end, the present invention provides a split-type refrigerator and its manufacturing method. By parametrically and modularly designing the cabinets of different capacity specifications and standardizing the cross-section of the frame components, the model differences are mainly transformed into changes in the length of the frame components. This allows the use of the same extrusion die to manufacture frame components required for multiple capacity specifications. Furthermore, the modular design of universal refrigeration units, universal interfaces, and small functional components improves the versatility of parts and molds.

[0007] To achieve the above objectives, one aspect of the present invention provides a method for manufacturing a split-type refrigerator, comprising: setting a universal refrigeration unit and a standard connection interface matching the universal refrigeration unit; designing a cabinet assembly according to a target capacity specification; disassembling the cabinet assembly into a frame assembly, plates, and functional components; the frame assembly including a top frame assembly, a vertical frame assembly, and a bottom frame assembly; ensuring that at least some of the same-named frame pieces in the cabinet assemblies of different capacity specifications have the same cross-sectional structure, and forming cabinet assemblies of different capacity specifications by changing the length of the frame pieces; manufacturing the frame pieces having the same cross-sectional structure using the same extrusion die; assembling the frame assembly, the plates, and the functional components to form the cabinet assembly, and connecting the cabinet assembly to the universal refrigeration unit to form a split-type refrigerator.

[0008] Furthermore, the enclosure components of different capacity specifications maintain consistent dimensions in at least two directions, and different capacity specifications are formed by changing the dimensions in another direction. In one embodiment, the width and depth of the enclosure remain constant, and different volumes are formed by changing the height of the enclosure and the length or height of the corresponding frame members, panels, and insulation layers.

[0009] Furthermore, the top border assembly includes a long top border, a short top border, and a top border connector; the bottom border assembly includes a long bottom border, a short bottom border, and a bottom border connector. For the same type of border component, its long and short borders adopt the same cross-sectional structure so that they can be continuously extruded through the same extrusion die and then cut to the required length.

[0010] Furthermore, the sheet metal is formed by at least one of extrusion molding, sheet metal forming, or vacuum forming to avoid forming large-sized box components entirely using large rotational molding or large injection molding molds.

[0011] Furthermore, the functional components include at least one of the following: air duct assembly, door latch assembly, handle assembly, and corner protector. Intricate or complex structures such as interfaces, latch seats, air duct openings, and corner connections can be centrally located on smaller, independent structural components, thereby allowing large-sized panels and frame components to maintain a relatively simple and regular shape.

[0012] Furthermore, at least some of the functional components are manufactured by injection molding; when manufacturing functional components of different specifications, a universal mold base and replaceable mold cores or inserts are used, and functional components of different specifications are formed by replacing the mold cores or inserts corresponding to the model differences.

[0013] Furthermore, the housing assembly includes multiple plates, adjacent plates are positioned and connected by a frame assembly and connectors, and are fixed by fasteners; a sealing element is provided at the connection position of the housing assembly, and the sealing element undergoes compression deformation in the connected state to seal the connection gap between the plates and the frame assembly.

[0014] Another aspect of the present invention provides a split-type refrigerator, including a universal refrigeration unit and a cabinet assembly connected to the universal refrigeration unit; the cabinet assembly includes a top frame assembly, a vertical frame assembly, a bottom frame assembly, a panel, and functional components; at least some of the frame members in the cabinet assemblies of different capacity specifications have the same cross-sectional structure, and different capacity specifications are formed by changing the length of the frame members.

[0015] Furthermore, the split-type refrigerator includes a door assembly, which includes an outer door panel, an inner door liner, a door frame, and a door frame connector; the door frame includes a long door frame and a short door frame, and the long door frame and the short door frame have the same cross-sectional structure.

[0016] Compared with the prior art, the present invention has at least the following beneficial effects: By fixing the refrigeration unit and its connection interface, and making the cabinets of different capacity models mainly formed by dimensional changes in one direction, the versatility of the main unit, interface, and related structural components can be significantly improved. By making the same long and short frames have the same cross-section, they can be manufactured using the same extrusion mold and adapted to different specifications by cutting the length, thereby reducing the number of large special molds. By concentrating complex functions into small injection molded parts and using universal mold frames and replaceable inserts, the mold investment when expanding the model can be further reduced. Through the detachable combination of plates, frame parts, and connectors, the cabinet can be disassembled and stacked for transportation, and it is convenient to replace and repair local parts. The use of panel insulation material can also avoid on-site overall foaming, which helps to reduce the weight of the cabinet and simplify assembly. Attached Figure Description

[0017] The above and / or additional aspects and advantages of the present invention will become apparent and readily understood from the following description of the embodiments taken in conjunction with the accompanying drawings, wherein: Figure 1 This is a schematic diagram of the overall structure of the split-type refrigerator of the present invention.

[0018] Figure 2 This is a schematic diagram of the structure of the gate component of the present invention.

[0019] Figure 3 This is a schematic diagram of the cross-sectional structure of the door frame of the present invention.

[0020] Figure 4 This is a schematic diagram of the frame structure of the housing assembly of the present invention after the top cover plate has been removed.

[0021] Figure 5 This is a schematic diagram of the bottom frame assembly and the inner liner of the base plate of the present invention.

[0022] Figure 6 This is a partially enlarged structural diagram of the frame connection position of the present invention.

[0023] Figure 7 This is a schematic flowchart of the manufacturing method of the split-type refrigerator of the present invention. Detailed Implementation

[0024] Embodiments of the present invention are described in detail below, examples of which are shown in the accompanying drawings, wherein the same or similar reference numerals denote the same or similar elements or elements having the same or similar functions throughout. The embodiments described below with reference to the accompanying drawings are used to explain the present invention and should not be construed as limiting the scope of protection of the present invention.

[0025] In this application, unless otherwise expressly specified and limited, the terms "connection," "fixing," "installation," etc., should be interpreted broadly. For example, they can refer to a fixed connection or a detachable connection; they can refer to a direct connection or an indirect connection through an intermediate structure. Those skilled in the art can understand the specific meaning of the above terms in this application based on the specific circumstances.

[0026] Example 1

[0027] Reference Figures 1 to 6 This embodiment provides a split-type refrigerator 10. The split-type refrigerator 10 includes a universal refrigeration unit and a cabinet assembly 12. The universal refrigeration unit can be connected to cabinet assemblies 12 of different capacity specifications using the same or compatible standard connection interfaces. Figure 1 The main illustration shows the housing assembly 12 and related structures disposed on the housing assembly 12. The general-purpose refrigeration unit can be disposed on one side, bottom or other suitable position of the housing assembly 12 according to the product layout.

[0028] The enclosure assembly 12 adopts a modular structure formed by combining frame assemblies, panels, and functional components 13. The frame assemblies are used to form the outer support and connecting skeleton of the enclosure assembly 12, and the panels are arranged between the corresponding frame assemblies to form the side walls, top, bottom, or door surface of the enclosure; the functional components 13 are used to realize functions such as air duct connection, door locking, handling, and corner protection.

[0029] like Figure 1As shown, functional component 13 may include an air duct assembly 131, a door latch assembly 132, a handle assembly 133, and corner protectors 134. The air duct assembly 131 is used to communicate with the cold air or return air duct of the refrigeration unit; the door latch assembly 132 is used to lock the door assembly 11 to the cabinet assembly 12; the handle assembly 133 is used to move the cabinet assembly 12 or the split-type refrigerator 10; the corner protectors 134 are located at the corners of the cabinet to protect the corner connection areas. At least some of the above functional components 13 can be made into independent small injection molded parts to achieve commonality between different capacity models or to achieve adaptation only through partial insert changes.

[0030] like Figure 2 As shown, the door assembly 11 includes an outer door panel 111, an inner door liner 112, a door frame 113, and a door frame connector 114. The outer door panel 111 can be made of sheet metal, the inner door liner 112 can be made of vacuum-formed material, and the door frame 113 surrounds the outer door panel 111 and the inner door liner 112 and is connected at the corners by the door frame connector 114. The door frame 113 includes a long door frame 1131 and a short door frame 1132.

[0031] like Figure 3 As shown, the long frame 1131 and the short frame 1132 of the door frame adopt the same cross-sectional profile. During manufacturing, profiles with this cross-sectional profile can be continuously extruded using the same extrusion die, and then cut according to the long and short side dimensions of the door assembly 11 to form the long frame 1131 and the short frame 1132 of the door frame. Therefore, changes in door size do not require the development of different cross-sectional dies for the long and short frames.

[0032] like Figure 4 As shown, the frame components of the housing assembly 12 include a top frame assembly 121, a vertical frame assembly 122, and a bottom frame assembly 123. The top frame assembly 121 includes a long top frame 1211, a short top frame 1212, and a top frame connector 1213; the vertical frame assembly 122 includes a left vertical frame 1221 and a right vertical frame 1222; and the bottom frame assembly 123 includes a long bottom frame 1231, a short bottom frame 1232, and a bottom frame connector 1233.

[0033] For the same type of top, bottom, or vertical frame, the frame components corresponding to different capacity specifications can maintain the same cross-sectional structure, only changing the cutting length of the profile. For long and short frames, the same cross-section can also be used, but different lengths can be cut according to the corresponding side lengths. Thus, the traditional three-dimensional integral mold changes caused by changes in box size can be converted into one-dimensional length changes of standard profiles.

[0034] like Figure 5As shown, the long bottom frame 1231 and the short bottom frame 1232 are connected by a bottom frame connector 1233 to form a bottom frame, and the bottom plate liner 124 is installed inside the bottom frame. The bottom plate liner 124 can be made by vacuum forming, sheet metal, or other processes suitable for forming a plate-like or shallow cavity structure. The same structural principle can also be applied to the top and side panels of the enclosure.

[0035] like Figure 6 As shown, a connection sealing assembly 14 is provided at the connection position between the frame and the connector or adjacent plate. The connection sealing assembly 14 includes a seal 141 and a fastener 142. The seal 141 can be made of EPDM foam strip or other elastic sealing material with compression resilience and is provided at the joint position of adjacent components; the fastener 142 can be screws, bolts, etc. After the fastener 142 is tightened, the seal 141 is compressed, thereby reducing or sealing the gap at the joint position and improving the airtightness and thermal insulation performance of the housing assembly 12.

[0036] The enclosure assembly 12 may include multiple detachable splicing panels. In one embodiment, the enclosure is formed by assembling six splicing panels. The side panels and bottom panels can be positioned and spliced ​​using profile tenons and grooves, and sealant is applied to the joints. The top panel can be fixed by clips, fasteners, or other detachable connection methods. XPE or EPE foam board can be provided as an insulation layer in the enclosure interlayer. The insulation layer can be pre-cut and embedded between the panels, eliminating the need for overall foaming at the user's assembly site.

[0037] Example 2

[0038] Reference Figure 7 This embodiment provides a method for manufacturing the aforementioned split-type refrigerator 10. The manufacturing method may include steps S101 to S107. The step numbers are for ease of explanation and do not imply that each step must be performed in a unique chronological order; where no technical conflict occurs, some steps may be adjusted in order, implemented in parallel, or combined.

[0039] Step S101: Set up a universal refrigeration unit and standard connection interfaces. For a product series, pre-determine the refrigeration unit structure that can be shared by multiple capacity models, as well as the air duct interface, installation interface, and / or electrical connection interface between the unit and the enclosure assembly 12, so that enclosure assemblies 12 of different capacity specifications can be connected to the universal refrigeration unit.

[0040] Step S102: Design the enclosure assembly 12. Step S102 may further include step S1021: determining at least two directional dimensions that maintain consistency between different capacity specifications; and step S1022: determining another directional dimension for changing the volume, as well as the dimensions of the frame members, panels, and insulation layer that vary with this direction. For example, the enclosure width and depth can be kept consistent, and different capacity specifications can be formed by changing the enclosure height.

[0041] Step S103: The housing assembly 12 is disassembled into a frame assembly, plates, and functional components 13. Among them, the larger, more regular-shaped structures that are mainly used to form the surface of the housing are designed as plates or profiles, while the complex local structures such as interfaces, locking seats, air ducts, and corner connections are concentrated in the smaller functional components 13 or connectors to reduce the molding complexity of large structural components.

[0042] Step S104: Manufacturing standardized frame components. Step S104 may further include step S1041: determining the standard cross-section of similar frame parts, so that corresponding frame parts in different capacity models maintain the same cross-section; and step S1042: continuously manufacturing profiles with the standard cross-section using the same extrusion die, and cutting them according to the length required for the target model, thereby forming a top frame long frame 1211, a top frame short frame 1212, corresponding vertical frames, and a bottom frame long frame 1231, a bottom frame short frame 1232, etc.

[0043] Step S105: Manufacturing sheet metal parts and functional components 13. Step S105 may further include step S1051: Manufacturing sheet metal parts such as the large panel of the box, the outer door panel 111, the inner door liner 112, or the inner bottom panel liner 124 using at least one of the following methods: extrusion, sheet metal, and vacuum forming; step S1052: Manufacturing at least some of the following components: the air duct assembly 131, the door latch assembly 132, the handle assembly 133, the corner protector 134, and the frame connector using injection molding; and step S1053: Using a universal mold frame in the injection mold and reserving an interface for replacing the mold core or insert, adapting to the local structural differences between different models by replacing the mold core or insert.

[0044] Step S106: Assemble the housing assembly 12. Step S106 may further include step S1061: Position and connect the panels using the top frame connector 1213, the bottom frame connector 1233, and the corresponding frame structures; step S1062: Arrange the sealing element 141 at the connection position; and step S1063: Fix the sealing element 141 using fasteners 142, snaps, tenons, or combinations thereof, so that the sealing element 141 is compressed and deformed to form a seal.

[0045] In step S107, the assembled cabinet assembly 12 is connected to the universal refrigeration unit through a standard connection interface to form a split-type refrigerator 10. During transportation, the cabinet assembly 12 can be packaged with its panels, frame parts, and functional components 13 flattened or stacked even before final assembly, while the universal refrigeration unit is packaged separately and compactly. The cabinet assembly and the unit connection are completed after arrival at the usage location.

[0046] In one exemplary platform design, the height of the general-purpose refrigeration unit can be set to 250mm, the width of the cabinet can be set to 300mm, and the depth of the cabinet can be set to 400mm. The cabinet height can vary from 150mm to 450mm to create different capacity models ranging from approximately 20L to 60L. The above dimensions are for illustrative purposes only and do not constitute a limitation on the scope of protection of this invention.

[0047] Taking the 30L and 45L models as examples, the two models can share the same refrigeration unit, quick-release latches, bottom support frame, air duct interface components, control board, sealing plugs, and cabinet interface components. However, the dimensions of parts such as side panels, door panels, and XPE insulation layers, which vary depending on the capacity, are determined according to the specific model. In the sample data provided by the customer, the total mold cost for the two models is approximately 150,000 RMB, which is significantly lower than the mold investment for two models using traditional rotational molding methods. The transport volume of the cabinet after being flattened and stacked is approximately 0.12m³. 3 Compared to the traditional packaged unit of approximately 0.28m, 3 It has decreased somewhat.

[0048] In the same example, the 30L model weighs approximately 6.5 kg, while the traditional rotational molding structure weighs approximately 11 kg. This weight difference mainly stems from the replacement of some thick-walled monolithic plastic structures with sheet metal, profiles, and sheet insulation materials such as XPE / EPE. Initial assembly can be completed in approximately 15 minutes, and assembly time can be further reduced with experience. The above-mentioned cost, volume, weight, and assembly time are exemplary design data provided to customers to illustrate the potential effects of the technical solution of this invention.

[0049] In addition to the above-described embodiments, large-size structural components can also be manufactured using methods such as profile welding, sheet metal bending and welding, vacuum forming, or blow molding; molds for functional components can use universal mold frames and replaceable inserts, or be combined with quick-change mold structures; connections between panels can be achieved using snap-fit, profile tongue and groove, screws, and decorative covers; insulation structures can also use materials such as aluminum foil composite reflective insulation layers, fiber-reinforced plastics, or honeycomb sandwich panels. As long as structural standardization and sharing of manufacturing resources can be achieved between different capacity models, the appropriate method can be selected based on specific product needs.

[0050] Those skilled in the art will understand that, without conflict, the above-described embodiments and their technical features can be combined with each other. The above descriptions are merely some embodiments of the present invention and are not intended to limit the scope of protection of the present invention; all equivalent substitutions, simple modifications, or improvements made within the spirit and principles of the present invention should be included within the scope of protection of the present invention.

Claims

1. A method for manufacturing a split-type refrigerator, characterized in that... include: A general-purpose refrigeration unit and a standard connection interface that matches the general-purpose refrigeration unit are provided; Design the enclosure components (12) according to the target capacity specifications. The housing assembly (12) is disassembled to form a frame assembly, a panel, and a functional assembly (13); The border components include a top border component (121), a vertical border component (122), and a bottom border component (123). At least some of the same-named frame members in the box assembly (12) of different capacity specifications have the same cross-sectional structure, and the box assembly (12) of different capacity specifications is formed by changing the length of the frame members. The frame members with the same cross-sectional structure are manufactured using the same extrusion die; The frame assembly, the plate and the functional component (13) are assembled to form the cabinet assembly (12), and the cabinet assembly (12) is connected to the general refrigeration unit to form a split refrigerator (10).

2. The manufacturing method of the split-type refrigerator according to claim 1, characterized in that: The enclosure assembly (12) of different capacity specifications maintains the same dimensions in at least two directions and forms different capacity specifications by changing the dimensions in another direction.

3. The manufacturing method of the split-type refrigerator according to claim 1, characterized in that: The top border assembly (121) includes a top border long border (1211), a top border short border (1212), and a top border connector (1213). The bottom border assembly (123) includes a long bottom border (1231), a short bottom border (1232), and a bottom border connector (1233). The long frame and the short frame have the same cross-sectional structure.

4. The manufacturing method of the split-type refrigerator according to claim 1, characterized in that: The sheet metal is formed by at least one of extrusion molding, sheet metal forming, or vacuum forming.

5. The manufacturing method of the split-type refrigerator according to claim 1, characterized in that: The functional component (13) includes at least one of the following: air duct assembly (131), door latch assembly (132), handle assembly (133), and corner protector (134).

6. The method for manufacturing a split-type refrigerator according to claim 5, characterized in that: At least some of the functional components (13) are manufactured by injection molding and are formed into functional components (13) of different specifications using a universal mold base and replaceable inserts.

7. The method for manufacturing a split-type refrigerator according to claim 1, characterized in that: The housing assembly (12) includes multiple plates, adjacent plates are positioned and connected by a frame assembly and connectors, and are fixed by fasteners (142).

8. The method for manufacturing a split-type refrigerator according to claim 7, characterized in that: A seal (141) is provided at the connection position of the housing assembly (12), and the seal (141) undergoes compression deformation in the connected state.

9. A split-type refrigerator (10), characterized in that... include: General-purpose refrigeration unit; The enclosure assembly (12) connected to the general-purpose refrigeration unit; The enclosure assembly (12) includes a top frame assembly (121), a vertical frame assembly (122), a bottom frame assembly (123), a panel, and a functional component (13). At least some of the frame members in the housing assembly (12) of different capacity specifications have the same cross-sectional structure, and different capacity specifications are formed by changing the length of the frame members.

10. The split-type refrigerator (10) according to claim 9, characterized in that: The door assembly (11) includes an outer door panel (111), an inner door liner (112), a door frame (113), and a door frame connector (114). The door frame (113) includes a long door frame (1131) and a short door frame (1132), and the long door frame (1131) and the short door frame (1132) have the same cross-sectional structure.

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