Insulated door for refrigerator, refrigerator, method for manufacturing an insulated door for refrigerator, and method for manufacturing door

Abstract

To provide a door in which flaws are inconspicuous, a refrigerator, and a manufacturing method for the door.SOLUTION: A door 11 according to the present invention comprises a base material 12, and a design part 13 formed on the base material 12. The design part 13 comprises a film 14 having hardness lower than that of iron. The film 14 comprises a plurality of layers, fine irregularities are formed in a surface of its outermost layer, and the thickness of the outermost layer is larger than 10 μm. A refrigerator 1 according to the present invention comprises the door 11. A manufacturing method for the door 11 according to the present invention comprises a stacking step S1 of stacking an ultraviolet curable resin 52 on a base material film, a design part manufacturing step S2 of manufacturing the design part 13 comprising the predetermined film 14, a laminate material manufacturing step S3 of laminating the film 14 on the base material 12 on which the design part 13 is formed, a forming step S4, an assembling step S5 of manufacturing an assembly, and a foam heat insulating material adding step S6 of manufacturing the door by adding a foam heat insulating material to the assembly.SELECTED DRAWING: Figure 3

Description

[Technical field]

[0001] The present invention relates to a door, a refrigerator, and a method for manufacturing the door. [Background technology]

[0002] Since the refrigerator door is a member that users often touch, it is conceivable to provide a pattern that does not show scratches, for example, fine unevenness on the surface. Such a door is disclosed, for example, in Patent Document 1. The refrigerator door disclosed in Patent Document 1 has unevenness formed on the outer surface of the glass plate (paragraph 0041, Figure 2). It is described that the unevenness is provided for the purpose of creating an antique feel and a sense of depth on the refrigerator door and enhancing the visual effect. It is also described that the unevenness has the effect of making dirt and scratches on the glass plate less noticeable compared to when the unevenness is not formed. It is described that the unevenness in Patent Document 1 has an average distance from one convex part to the next convex part that is smaller than the thickness of a user's finger (paragraph 0042). As a specific distance, it is described that the thickness of a user's finger is, for example, 10 mm when it is thin (paragraph 0020). Furthermore, when the glass plate is a patterned glass, the height difference between the convex portion and the concave portion continuing from the convex portion is described as, for example, 0.1 mm to 1.0 mm on average (paragraph 0021). In other words, the concaves and convexes of the refrigerator door disclosed in Patent Document 1 are obtained by forming the convex portions and concave portions of the glass plate into the above-mentioned shapes. [Prior art documents] [Patent documents]

[0003] [Patent Document 1] JP 2018-200163 A (paragraphs 0041, 0042, 0020, 0021, and FIG. 2) Summary of the Invention [Problem to be solved by the invention]

[0004] On the other hand, fine irregularities can also be imparted to the door of a refrigerator by, for example, laminating a film having an irregular surface onto the outermost layer of the door. A press machine may be used when laminating a film on the substrate of the door and when bending the substrate, which may be performed thereafter. If the door is an insulated door, a foaming tool may be used in the foaming urethane filling process. The foaming tool is a tool that prevents the door from being deformed by the foaming of the resin in the foaming urethane filling process. In an environment where a press machine or a foaming tool is used, there is a risk of iron powder being present in the surroundings due to the operation of these tools. If iron powder is present during the pressing or foaming process on a hard door surface that has been subjected to uneven processing, there is a risk of damaging the surface of the door by using the press machine or the foaming tool. Furthermore, if iron powder is present, there is a risk of damaging the surface of the press machine or the foaming tool.

[0005] The technology described in Patent Document 1 does not take into consideration the environment in which the press machine or the foamed material is used. Naturally, the technology described in Patent Document 1 does not take into consideration the presence of iron powder in the environment in which the press machine or the foamed material is used. Therefore, for example, if a press machine or the foamed material is used in the manufacture of a refrigerator door as disclosed in Patent Document 1, the surface of the refrigerator door will be damaged by the iron powder, resulting in a defective product. [Means for solving the problem]

[0006] The present invention has been made in view of the above circumstances. The present invention Insulation for refrigerators The door is It is either a steel plate, a glass plate, or a plastic plate. A substrate and a design portion formed on the substrate, the design portion having a film having a hardness less than that of iron, the film being made of a plurality of layers, the surface of the outermost layer of the film being provided with fine irregularities, and the thickness of the outermost layer being greater than 10 μm. Has injected foam insulation It is characterized by: [Brief description of the drawings]

[0007] [Figure 1] FIG. 1 is a front view illustrating a configuration of a refrigerator 1 to which a door 11 according to one embodiment is applied. [Diagram 2] FIG. 1 shows the door 11f of the second switchable chamber 6 as an example of the door 11, and is an exploded perspective view of the door 11f as seen obliquely from the front. [Diagram 3] FIG. 2 is a schematic cross-sectional view illustrating the configuration of the front surface of a door 11 according to an embodiment of the present invention. [Figure 4] 1 is a flowchart illustrating the details of a manufacturing method for the door 11 according to an embodiment of the present invention. [Diagram 5] 1 is a schematic diagram illustrating a lamination step S1 and a design portion manufacturing step S2. FIG. [Figure 6] FIG. 2 is a schematic diagram illustrating a laminate material manufacturing process S3. [Figure 7A] 1 is a schematic cross-sectional view showing a laminate material 61 being unwound from a rolled state. [Figure 7B] FIG. 2 is a schematic cross-sectional view showing a laminate material 61 after molding. [Figure 8] 10 is a flowchart illustrating an example of a foam insulating material applying step S6. [Figure 9A] FIG. 11 is a schematic cross-sectional view illustrating a state of an injection step S62a. [Figure 9B] FIG. 11 is a schematic cross-sectional view illustrating the foaming and sealing step S63a. [Figure 9C] FIG. 11 is a schematic cross-sectional view illustrating the foaming and sealing step S63a. [Figure 10] 10 is a flowchart illustrating another example of the foam insulating material applying step S6. [Figure 11A] 13 is a schematic cross-sectional view illustrating a state of a receiving step S61b. FIG. [Figure 11B] FIG. 11 is a schematic cross-sectional view illustrating a sealing step S62b. DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

[0008] Hereinafter, a door, a refrigerator, and a method for manufacturing a door according to one embodiment of the present invention will be described in detail with reference to the drawings as appropriate. Before describing the door according to one embodiment of the present invention, the overall configuration of a refrigerator to which the door according to this embodiment is applied will be described. Fig. 1 is a front view illustrating the configuration of a refrigerator 1 to which a door 11 according to one embodiment is applied.

[0009] (refrigerator) As shown in Fig. 1, refrigerator 1 has, from the top, a refrigerator compartment 2, an ice-making compartment 3, a freezer compartment 4 (first freezer compartment), a first switchable compartment 5, and a second switchable compartment 6. First switchable compartment 5 may be a freezer compartment (second freezer compartment). The internal volume of freezer compartment 4 may be smaller than the internal volume of first switchable compartment 5.

[0010] The refrigerator compartment 2 is set to a refrigerator temperature range (for example, 6° C.). Ice making compartment 3 and freezer compartment 4 are set to a freezing temperature range. The temperature zone of the first selectable compartment 5 can be switched from a refrigerated temperature zone (for example, 1° C. to 6° C.) to a long-term frozen storage temperature zone (for example, about −20° C. to −15° C., preferably −18° C. or lower). Similarly, the second selectable compartment 6 can also be switched between a temperature range from a refrigerated storage temperature range to a long-term frozen storage temperature range. In this embodiment, the temperature zone higher than the long-term frozen storage temperature zone may be a frozen storage temperature zone (for example, −10° C. to −14° C., preferably about −12° C.). Since there is a risk that the food may not be completely frozen, in this embodiment, the upper limit temperature of the frozen storage temperature zone is preferably −6° C.

[0011] In this embodiment, the first and second switchable compartments 5 and 6 are described as being switchable between a refrigeration temperature zone and a long-term frozen storage temperature zone, but the present invention is not limited to this configuration. For example, the first and second switchable compartments 5 and 6 arranged vertically may be storage compartments (freezer temperature zone compartments or refrigeration temperature zone compartments (refrigerator compartment, vegetable compartment, etc.)) in which the temperature zone cannot be switched.

[0012] The refrigerator 1 having the above-mentioned configuration has six doors 11 as shown in FIG. 1. In this embodiment, each door 11 has an inner wall and an outer wall (see FIG. 2), and a foam insulation material (not shown) is provided between them. FIG. 2 shows the door 11f of the second switching chamber 6 as an example of the door 11, and is an exploded perspective view of the door 11f seen from the diagonal front. As shown in FIG. 2, the door liner 10 corresponds to the inner wall, and the front door outer plate 7, the upper frame part 8 at the upper part, and the lower frame part 9 at the lower part correspond to the outer wall. The foam insulation material is, for example, urethane foam, but is not limited to this and any foamable resin that can insulate the inside of the refrigerator from the outside space can be used. The foam insulation material may be one that is foamed by injecting a resin for foam insulation material into the inside of the door 11, or one that contains a foam insulation material that has been molded in advance. With this configuration, the door 11 can insulate the inside of the refrigerator from the outside space. In other words, the door 11 is a heat-insulating door. Additionally, the door 11 serves to open and close the opening 10a at the front side of the heat-insulating box 1H of the refrigerator 1. Although Fig. 2 illustrates the door 11f, the doors 11a to 11e also have the same configuration.

[0013] The insulating box 1H constitutes the entire area of ​​the refrigerator 1 except for the front surface, i.e., the top, bottom, both side walls, and back surface of the refrigerator 1. The insulating box 1H also has inner and outer walls (neither of which are shown), and a foam insulating material (not shown) is provided between them. The foam insulating material may be the same as that described above. With this configuration, the insulating box 1H can insulate the interior of the refrigerator from the outside space.

[0014] As shown in FIG. 1, the refrigerator compartment 2 has two doors 11a, 11b. The left door 11a is pivotally attached by a pair of upper and lower door hinges (not shown) provided on the left side of the refrigerator 1. The right door 11b is pivotally attached by a pair of upper and lower door hinges (not shown) provided on the right side of the refrigerator 1. In other words, the left door 11a and the right door 11b are provided on the front side of the refrigerator 1 so as to open like a double door. The door hinges provided on the left and right sides of the upper part of the refrigerator 1 are covered with door hinge covers 19.

[0015] Ice making compartment 3 has one door 11c. Freezing compartment 4 has one door 11d. First selectable compartment 5 has one door 11e. Second selectable compartment 6 has one door 11f. Doors 11c to 11f are each provided so as to be able to be pulled out to the front side of refrigerator 1.

[0016] The number of doors 11 of the refrigerator 1 is not limited to six, and may be one, two, three, four, five, or seven or more. The number of doors 11 can be set arbitrarily depending on the size of the refrigerator 1 and the number of refrigerating compartments 2, etc. The door 11 according to this embodiment can be suitably used in any of the refrigerators 1 described above.

[0017] In addition, in this embodiment, the operation unit 26 is provided on the door 11a of the refrigerator compartment 2, but the present invention is not limited to this configuration. For example, the operation unit 26 may be provided on either the left or right side wall inside the refrigerator compartment 2.

[0018] (door) Next, the door 11 according to one embodiment of the present invention will be described. Fig. 3 is a schematic cross-sectional view illustrating the configuration of the surface of the door 11 according to one embodiment of the present invention. As described above, the door 11 is suitably used for the refrigerator 1. As shown in Fig. 3, door 11 has base material 12 and design portion 13. Design portion 13 has film 14 with a hardness less than that of iron. Film 14 is made of multiple layers, with the surface of the outermost layer having fine irregularities, and the thickness T1 of the outermost layer being greater than 10 µm.

[0019] The base material 12 is formed of, for example, a steel plate, a glass plate, a plastic plate, etc. The base material 12 is a base on which the design portion 13 is formed, and also plays a role in maintaining the rigidity of the door 11.

[0020] The design portion 13 has a printed portion 15 in addition to the film 14 described above. The printed portion 15 is printed with a color of your choice to enhance the design of the door 11. The printed portion 15 can be formed by a known printing technique. A primer layer 16 is provided between the printed portion 15 and the base material 12, which firmly bonds the printed portion 15 to the base material 12 and enhances the color development of the printed portion 15.

[0021] As described above, the film 14 is made up of a plurality of layers. The film 14 is made up of, for example, a transparent resin layer 17 and an ultraviolet curing resin layer 18. In this embodiment, the ultraviolet curing resin layer 18 is the outermost layer of the film 14. In this embodiment, the thickness T1 of the ultraviolet curing resin layer 18 (outermost layer) is made larger than 10 μm. As a result of the inventor's research into iron powder present in the environment in which a press machine or a foaming agent is used, the maximum diameter of the iron powder was about 10 μm. Therefore, by making the thickness T1 of the ultraviolet curing resin layer 18 larger than 10 μm, even if iron powder is present in the environment in which a press machine or a foaming agent is used, the iron powder can be made less likely to penetrate the ultraviolet curing resin layer 18. In addition, the iron powder can be made to bite into (be embedded in) the ultraviolet curing resin layer 18. At this time, in this embodiment, since the thickness of the ultraviolet curing resin layer 18 is made larger than 10 μm, almost all of the iron powder embedded in the film 14 does not exceed the thickness of the ultraviolet curing resin layer 18, which is the outermost layer. In addition, "substantially the entirety" means, for example, 80% or more, 90% or more, 95% or more, 99% or more, or 99.9% or more in an arbitrary observation range using an optical microscope or the like. From this viewpoint, the thickness T1 of the ultraviolet cured resin layer 18 (outermost layer) is preferably 11 μm or more, 15 μm or more, or 20 μm or more. On the other hand, even if the thickness T1 of the ultraviolet cured resin layer 18 (outermost layer) is too thick, the amount of the ultraviolet cured resin layer 18 formed increases, although the above-mentioned effect remains unchanged, and therefore economic efficiency is reduced. From this viewpoint, the thickness T1 of the ultraviolet cured resin layer 18 (outermost layer) is preferably 29.5 μm or less, or 25 μm or less. Furthermore, the thickness T2 formed by the lowest portion of the unevenness of the ultraviolet cured resin layer 18 and the transparent resin layer 17 can be, for example, 11 to 17 μm, but is not limited to this.

[0022] Examples of situations in which a press machine or a foaming roller is used include using a press machine when laminating film 14, using a press machine to perform bending processing on film 14 that is laminated, and using a foaming roller to foam-fill foam insulation material on film 14 that is laminated.

[0023] As shown in FIG. 3, the thickness T3 of the film 14, that is, the total thickness T3 of the transparent resin layer 17 and the ultraviolet cured resin layer 18, is preferably at most 100 μm, but is not limited to this. The thickness T1 of the ultraviolet cured resin layer 18, the thickness T2 formed by the lowest part of the ultraviolet cured resin layer 18 and the transparent resin layer 17, the maximum diameter of the iron powder, and the thickness T3 of the film 14 can all be confirmed using an optical microscope or the like.

[0024] As described above, the ultraviolet curing resin layer 18, which is the outermost layer, has fine irregularities. The ten-point average roughness Rz of the ultraviolet curing resin layer 18, which is the outermost layer, formed by the fine irregularities jis is preferably, for example, greater than 10 μm. With this lower limit, as described above, since the maximum diameter of iron powder is about 10 μm, even if the ultraviolet cured resin layer 18 is scratched by iron powder when using a press or a foaming machine, such scratches can be made less noticeable. Therefore, even refrigerators 1 in which scratches have been caused by iron powder in the ultraviolet cured resin layer 18 can be treated as non-defective products. This makes it possible to improve the yield rate of refrigerators 1. From this perspective, the ten-point average roughness Rz of the ultraviolet cured resin layer 18, which is the outermost layer, can be reduced by 10 μm. jis On the other hand, from the viewpoint of improving the appearance and the feel, the ten-point average roughness Rz of the ultraviolet cured resin layer 18, which is the outermost layer, is preferably 10.2 μm or more. jis is preferably, for example, 12.5 μm or less, but is not limited to this. The surface roughness Rz can be obtained, for example, in accordance with JIS B 0601:2001 and JIS B 0031:2001.

[0025] As described above, the film 14 has a hardness less than that of iron. When the hardness of the film 14 is less than that of iron, the film 14 has a lower hardness than the press machine or the foamed material, so that when the press machine or the foamed material is used, the surface of the press machine or the foamed material is less likely to be damaged by fine irregularities on the surface of the outermost layer of the film 14. Furthermore, by making the hardness of the film 14 less than that of iron, even if iron powder is present in the usage environment (i.e., between the press machine or the foamed material and the film 14) when a press machine or a foamed material is used for the door 11, the iron powder can be embedded in the film 14. Therefore, it is possible to make it difficult for the iron powder to scratch the surface of the press machine or the surface of the foamed material. The hardness of the film 14 which is less than that of iron may be achieved by cooperation between the transparent resin layer 17 and the ultraviolet curable resin layer 18, or may be achieved by the ultraviolet curable resin layer 18 alone. The hardness of the film 14 can be adjusted by changing the blending components and blending ratios of the resins described below used in each layer of the transparent resin layer 17 and / or the ultraviolet cured resin layer 18. This adjustment can be appropriately performed based on known techniques in the technical fields that handle these resins.

[0026] The hardness of the film 14 is preferably a pencil hardness of 2H or more and less than 7H. The hardness of a fingernail is considered to be about 2H in pencil hardness. The hardness of iron is considered to be about 7H in pencil hardness. Therefore, if the pencil hardness of the film 14 is 2H or more and less than 7H, the film 14 is less likely to be scratched by a user's fingernail, and as described above, the surface of the press machine or the foamed material is less likely to be scratched by the fine irregularities on the surface of the outermost layer of the film 14. Furthermore, when a press machine or a foamed material is used on the door 11, even if iron powder is present in the usage environment, the surface of the press machine or the foamed material is less likely to be scratched by the iron powder. The pencil hardness of the film 14 can be determined, for example, in accordance with JIS K 5600-5-4 "General test methods for paints - Part 5: Mechanical properties of coatings - Section 4: Scratch hardness (pencil method)".

[0027] The transparent resin layer 17 is provided to protect the printed portion 15. The transparent resin layer 17 is formed of a transparent or semi-transparent resin so that the color of the printed portion 15 can be seen. The transparent resin layer 17 can be formed of a known resin such as a polyethylene terephthalate (PET) resin, an acrylic resin, or an epoxy resin.

[0028] The ultraviolet curing resin layer 18 is also provided to protect the printed portion 15. The ultraviolet curing resin layer 18 is also formed of a transparent resin. In this embodiment, as described above, the ultraviolet curing resin layer 18, which is the outermost layer, has fine irregularities on its surface. It is preferable that the ultraviolet curing resin layer 18 has a vibration pattern formed by the fine irregularities on its surface. The vibration pattern refers to a pattern having a fine radial pattern, a swirl pattern, or a pattern that looks like random scratches. The vibration pattern can make scratches caused by using a press or foaming machine on the door 11 less noticeable due to its characteristic scratch-like pattern. Therefore, even a refrigerator 1 with scratches on the ultraviolet curing resin layer 18 caused by iron powder can be treated as a good product. In addition, since the particle size distribution of the iron powder may differ depending on the equipment used, such as the press machine or the foaming machine, which may generate iron powder during operation, it is preferable to measure the particle size of the iron powder around the press machine or the foaming machine in advance.

[0029] The ultraviolet curing resin is polymerized and cured in a short time by the ultraviolet energy irradiated from the ultraviolet irradiation device. Therefore, by forming fine irregularities on the surface of the ultraviolet curing resin using a metal roller formed with irregularities corresponding to the fine irregularities, and then irradiating ultraviolet rays with the ultraviolet irradiation device to polymerize and cure, it is possible to suitably obtain the ultraviolet curing resin layer 18 having fine irregularities on its surface. The fine irregularities on the surface of the ultraviolet curing resin layer 18 can also be obtained by forming the ultraviolet curing resin layer 18 having a smooth surface and then performing vibration polishing on the smooth surface. The ultraviolet curing resin may be, for example, an acrylic resin, an epoxy resin, or the like, and any known resin that can be cured by ultraviolet light may be used.

[0030] (Door manufacturing method) Next, a method for manufacturing the door 11 according to one embodiment of the present invention (hereinafter, sometimes referred to as this manufacturing method) will be described. Fig. 4 is a flowchart for explaining the details of the method for manufacturing the door 11 according to one embodiment of the present invention. As shown in FIG. 4, this manufacturing method includes a lamination step S1, a design portion manufacturing step S2, a laminate material manufacturing step S3, a molding step S4, an assembly step S5, and a foam insulation material applying step S6.

[0031] In the lamination step S1, an ultraviolet curing resin is laminated on one side of a base film. The base film corresponds to the transparent resin layer 17 described above. That is, the base film is a film-like member formed of a known resin such as PET resin, acrylic resin, or epoxy resin. The ultraviolet curing resin is in a liquid state having a predetermined viscosity when laminated. In the lamination step S1, lamination is performed by applying the liquid ultraviolet curing resin to one side of the base film.

[0032] The lamination step S1 can be performed, for example, by applying a liquid ultraviolet curing resin 52 to one surface 51a of a base film 51 transported by a roll-to-roll method, as shown in Fig. 5. Fig. 5 is a schematic diagram for explaining the lamination step S1 and the design portion manufacturing step S2. The ultraviolet curing resin 52 can be laminated by an appropriate method such as resin flow, a bar coater, a rod coater, or a spray. The ultraviolet curing resin 52 is laminated by adjusting the thickness so that the thickness after the design portion manufacturing step S2 described below is greater than 10 μm.

[0033] In the design part manufacturing process S2, a metal roller 53 having fine irregularities formed on its surface is used to apply the irregularities to the ultraviolet curing resin 52 while irradiating it with ultraviolet rays 54, curing the ultraviolet curing resin 52 to apply fine irregularities to the surface of the outermost layer, and the thickness T1 of the outermost layer (ultraviolet curing resin layer 18) is made greater than 10 μm, and the design part 13 is manufactured with a film 14 having a hardness less than that of iron. The irregularities formed on the surface of the metal roller 53 are transferred to the ultraviolet curing resin 52, and irregularities corresponding to the irregularities are formed in the ultraviolet curing resin 52. By irradiating ultraviolet rays 54 in this state, the ultraviolet curing resin 52 quickly hardens and becomes less hard than iron, and the film 14 with the irregularities described above is manufactured. The ultraviolet rays 54 can be irradiated by a known ultraviolet irradiation device 55. In the design part manufacturing process S2, after irradiation with ultraviolet light 54, an arbitrary color is printed on the other side 51b of the base film 51 to form the printed part 15 (not shown in FIG. 5). As described above, the printed part 15 can be formed by a known printing technique. Note that the printed part 15 may be formed on the other side 51b of the base film 51 before irradiation with ultraviolet light 54, as long as there is no problem with the irradiation with ultraviolet light 54.

[0034] In the laminate material production step S3, a lamination process is carried out in which the substrate 12 and the other surface 51b of the substrate film 51 are brought into close contact with each other so as to face each other, thereby producing a laminate material 61. FIG. 6 is a schematic diagram for explaining the laminate material manufacturing process S3. As shown in FIG. 6, the laminate material manufacturing process S3 can also be manufactured, for example, by a roll-to-roll method. Specifically, as shown in FIG. 6, the film 14, which is also transported by the roll-to-roll method, is laminated onto the substrate 12, which is transported by the roll-to-roll method. Since the film 14 has a printed portion 15 formed on the other surface 51b of the substrate film 51, the film 14 is laminated by bringing the other surface 51b of the substrate film 51 (i.e., the printed portion 15) and the substrate 12 into close contact with each other. These laminations (bonding) can be performed by a pressure roller 62. This allows the laminate material 61 to be manufactured suitably. The laminate material manufacturing process S3 can also be performed by a press machine.

[0035] In the forming step S4, the laminate material 61 is formed. The laminate material 61 can be formed by unwinding it from a rolled state (see FIG. 7A), cutting it to the required dimensions and shape, punching it out, pressing it using a press, or any other mechanical processing (see FIG. 7B). FIG. 7A is a schematic cross-sectional view showing the laminate material 61 unwound from a rolled state. FIG. 7B is a schematic cross-sectional view showing the laminate material 61 after it has been formed.

[0036] In this embodiment, as described above, the ultraviolet curing resin 52 of the laminate material 61 has a fine unevenness on its surface (see FIG. 3). Therefore, even if the surface is scratched by iron powder when using a press, the scratch can be made less noticeable. This effect is more pronounced when a vibration pattern is applied by the fine unevenness. Therefore, even if a refrigerator 1 has scratches on the ultraviolet curing resin layer 18 caused by iron powder, it can be treated as a non-defective product. In addition, since the film 14 has a hardness less than that of iron, the fine unevenness on the surface of the outermost layer of the film 14 will not scratch the press or the surface of the foamed material.

[0037] In the assembly process S5, an assembly is manufactured using the molded laminate material 61 and other parts (see FIG. 2). The door outer panel 7 in FIG. 2 corresponds to the molded laminate material 61. The upper frame part 8, the lower frame part 9, and the door liner 10 in FIG. 2 correspond to the other parts in this process. In this assembly process S5, for example, any two of the upper frame part 8, the lower frame part 9, and the door liner 10 are assembled with the door outer panel 7 (molded laminate material 61) to form an assembled product. Of the upper frame part 8, the lower frame part 9, and the door liner 10, the parts not used in the assembly in this process are used as other parts 95 (see FIG. 9B) or other parts 113 (see FIG. 11B) when sealing the foam insulation when or after foam insulation is applied to the assembly in foam insulation application process S6 described below.

[0038] In the foam insulation application step S6, foam insulation is applied to the assembly and sealed as described above to produce the door 11. There are two methods for applying the foam insulation to the assembly in the foam insulation application step S6. (1) One is to inject a resin for foam insulation into the assembly, and (2) the other is to place a preformed foam insulation inside the assembly. The door 11 can be manufactured by either of these methods.

[0039] FIG. 8 is a flow chart illustrating an example of the foam insulating material applying step S6. As shown in FIG. 8, the method (1) includes a setting step S61a, an injection step S62a, and a foaming and sealing step S63a. Here, Fig. 9A is a schematic cross-sectional view illustrating the injection step S62a, and Fig. 9B and Fig. 9C are schematic cross-sectional views illustrating the foaming and sealing step S63a.

[0040] In the setting step S61a, the assembly 91 is set in a foaming material 92 (see FIG. 9A for both). In the injection step S62a, as shown in FIG. 9A, a foaming heat insulating resin 93 is injected into the assembly 91 set in the foaming chamber 92. In the foaming and sealing step S63a, as shown in Fig. 9B, the injected foam insulation resin 93 is foamed to form foam insulation 94, while other members 95 are attached to the assembly 91 and sealed, to produce the door 11 as shown in Fig. 9C. The assembly 91 and other members 95 can be fixed by any means such as adhesion, fusion, or screw fastening.

[0041] FIG. 10 is a flow chart illustrating another example of the foam insulating material applying step S6. As shown in FIG. 10, the method (2) includes, for example, a housing step S61b and a sealing step S62b. Here, Fig. 11A is a schematic cross-sectional view illustrating the accommodation step S61b, and Fig. 11B is a schematic cross-sectional view illustrating the sealing step S62b.

[0042] 11A, foam insulation material 112, which has been preformed so as to fit inside assembly 111, is accommodated inside assembly 111. Note that, as long as foam insulation material 112 can be sealed in the next sealing step S62b, a part of foam insulation material 112 may protrude outside assembly 111 in accommodation step S61b. 11B, in the sealing step S62b, other members 113 are attached to the assembly 111 containing the foam insulation material 112 to seal the foam insulation material 112, thereby manufacturing the door 11. The assembly 111 and other members 113 can be fixed together by any means such as adhesion, fusion, or screw fastening.

[0043] The door 11, the refrigerator 1, and the method for manufacturing the door 11 according to the present invention have been described in detail above with reference to the embodiments, but the present invention is not limited to the above-mentioned embodiments and includes various modified examples. For example, the above-mentioned embodiments have been described in detail to easily explain the present invention, and the present invention is not necessarily limited to those including all of the configurations described above. In addition, it is possible to replace a part of the configuration of one embodiment with the configuration of another embodiment, and it is also possible to add the configuration of another embodiment to the configuration of one embodiment. In addition, it is possible to add, delete, or replace a part of the configuration of each embodiment with another configuration. [Explanation of symbols]

[0044] 1. Refrigerator 1H Insulated box 2 Refrigerator 3 Ice Room 4 Freezer 5 First change room 6. Second Switch Room 7 Door outer panel 8 Upper frame parts 9 Lower frame parts 10 Door Liner 10a opening 11, 11a~11f Doors 12 Base material 13 Design Department 14 Film 15 Printing Department 16 Primer layer 17 Transparent resin layer 18 Ultraviolet curing resin layer 19 Door hinge cover 26 Control section 51 Base film 51a One side of the base film 51b The other side of the base film 52 UV curing resin 53 Metal Roller 54 UV rays 55 Ultraviolet irradiation device 61 Laminate material 62 Pressure Roll 91 Assembly 92 Foam Employment 93 Resin for foam insulation 94 Foam insulation 95 Other materials 111 Assembly 112 Foam insulation 113 Other parts S1 Lamination process S2 Design department manufacturing process S3 Laminate manufacturing process S4 Molding process S5 Assembly Process S6 Foam insulation application process S61a Set process S62a injection process S63a Foaming and sealing process S61b Containment process S62b Sealing process T1~T3 thickness

Claims

1. A substrate which is any one of a steel plate, a glass plate, and a plastic plate; A design portion formed on the base material, The design portion has a film having a hardness less than that of iron, The film is made of a plurality of layers, the surface of the outermost layer of which is provided with fine irregularities, the thickness of the outermost layer is greater than 10 μm, and the outermost layer has a foamed insulation material injected and foamed.

2. In claim 1, The ten-point average roughness Rz of the outermost layer ｊｉｓ The insulating door for a refrigerator is characterized in that the thickness is greater than 10 μm and less than 12.5 μm.

3. In claim 1, The insulating door for a refrigerator is characterized in that iron powder is embedded in the surface of the outermost layer of the film.

4. A refrigerator comprising the insulating door for a refrigerator according to any one of claims 1 to 3 (excluding those in which the thickness of the backer layer of the substrate is 120 to 250 μm and the Martens hardness measured using a surface film physical property tester (PICODENTOR HM-500, manufactured by Fischer Instruments) is 50 to 80 N / mm 2 ).

5. A method for manufacturing an insulated door for a refrigerator, comprising the step of injecting foam insulation material into an assembly obtained by assembling an outer door panel from a substrate selected from the group consisting of a steel plate, a glass plate, and a plastic plate, the substrate having an outermost layer of ultraviolet-cured resin with a thickness of more than 10 μm and a film with a hardness less than that of iron laminated thereto, the substrate being an outermost layer of ultraviolet-cured resin with a thickness greater than 10 μm and having a thickness greater than 10 μm, the step comprising the steps of: A method for manufacturing an insulated door for a refrigerator, characterized in that foaming agent is used in the injection step.

6. a lamination step of laminating an ultraviolet curable resin on one surface of the base film; a design part manufacturing process in which a metal roller having a fine unevenness formed on its surface is used to apply the unevenness to the ultraviolet curing resin while irradiating the resin with ultraviolet light, thereby hardening the ultraviolet curing resin to apply fine unevenness to the surface of the outermost layer, and the thickness of the outermost layer is made greater than 10 μm and the design part is provided with a film having a hardness less than that of iron; a lamination process for manufacturing a laminate material by laminating the substrate and the other surface of the substrate film so that the substrate and the other surface of the substrate film face each other; a molding step of molding the laminate material; an assembly process for manufacturing an assembly using the molded laminate material and other components; a foam insulation application step of applying a foam insulation material to the assembly to manufacture a door; A method for manufacturing a door, comprising the steps of:

7. In claim 6, A method for manufacturing a door, wherein the molding step is carried out by pressing using a press machine.

8. In claim 6 or 7, The foam insulation material application step includes: a setting step of setting the assembly in a foaming material; an injection step of injecting a foam insulation resin into the assembly set in the foaming machine; a foaming and sealing process in which the injected foam insulation resin is foamed to form a foam insulation material, while other components are attached to the assembly to seal the foam insulation material, thereby manufacturing the door; A method for manufacturing a door, comprising the steps of:

9. In claim 6 or 7, The foam insulation material application step includes: a step of housing a foam insulation material preformed to fit inside the assembly inside the assembly; a sealing process for assembling other members to the assembly containing the foam insulation material to seal the foam insulation material and manufacture the door; A method for manufacturing a door, comprising the steps of:

Images