Household electric appliance, refrigerator, and vacuum cleaner

Abstract

[Problem] To enhance the usage ratio of recycled resin and prevent a user from visually recognizing that the recycled resin is used in a resin component of a household electrical appliance manufactured by means of vacuum molding or the like. [Solution] A household electrical appliance comprising a resin component that is a laminated resin member including a recycled resin layer and a virgin resin layer, the resin component having a flat surface portion and a curved surface portion, wherein: the curved surface portion has a configuration in which the resin structure is stretched toward the flat surface portion; and the color difference between the curved surface portion and the flat surface portion in the virgin resin layer, which is disposed on the surface of the resin component, is 2.0 or less.

Description

Home appliances, refrigerators, vacuum cleaners

[0001] The present disclosure relates to home appliances, refrigerators, and vacuum cleaners.

[0002] From the viewpoint of effective utilization of resources, there is a demand to recycle waste plastics into recycled plastics (recycled resins).

[0003] Patent Document 1 discloses an inner box material for an insulating box of a refrigerator or the like, which contains recycled polyethylene terephthalate resin (PET resin) with excellent chemical resistance. Patent Document 1 also discloses that the material for the interior of the inner box is virgin polyethylene terephthalate resin, and the material on the side in contact with the foam insulation is polyethylene terephthalate resin containing recycled polyethylene terephthalate resin.

[0004] Japanese Patent Application Laid-Open No. 2002-22352

[0005] It is inevitable that foreign matter will be mixed into recycled resin. For this reason, recycled resin is usually treated to be black, gray, or other colors to hide the foreign matter exposed on the surface of the recycled resin.

[0006] In addition, recycled resins can raise hygiene concerns, so in products that store food, such as refrigerators, it is currently difficult to accept using recycled resin for the surfaces of parts that may come into direct contact with food.

[0007] The inner box of a refrigerator is formed by vacuum forming. The plate is made by molding two layers of recycled resin (e.g., black or gray) and virgin material (any color can be selected). When the vacuum forming process is performed, the plate is stretched at sharply curved areas, such as corners and ridges. In these stretched areas, the virgin material is thinner than the rest of the material, and the color of the recycled resin behind it can sometimes show through.

[0008] The purpose of the present disclosure is to increase the proportion of recycled resin used in plastic parts of home appliances that are manufactured by vacuum forming or the like, by preventing users from seeing that recycled resin is used.

[0009] The home appliance of the present disclosure comprises a resin part that is a laminated resin member including a recycled resin layer and a virgin resin layer and has a flat portion and a curved portion, the curved portion having a configuration in which the resin structure is stretched toward the flat portion, and the color difference between the curved portion and the flat portion in the virgin resin layer arranged on the surface of the resin part is 2.0 or less.

[0010] FIG. 1 is a front view showing a refrigerator of Example 1. FIG. 2 is a partial front view showing the interior of the refrigerator of Example 1. FIG. 3 is a partial perspective view showing the interior of the refrigerator of Example 1. FIG. 4 is a partial front view showing the refrigerator of FIG. 2 with the food shelf removed. FIG. 5 is a cross-sectional view showing the interior of the refrigerator of FIG. 4. FIG. 5 is a partial front view showing the refrigerator of FIG. 4 with the cold air duct panel removed. FIG. 6 is a schematic cross-sectional view showing a resin member formed by two-layer molding using a vacuum molding method. FIG. 7 is a partial front view showing a modified cold air duct panel. FIG. 8 is a partial front view showing the interior of a refrigerator of Modified Example 2. FIG. 9 is an exploded perspective view showing a modified food shelf. FIG. 10 is an overall perspective view showing an electric vacuum cleaner of Example 2.

[0011] Hereinafter, an embodiment will be described with reference to the drawings.

[0012] FIG. 1 is a front view showing a refrigerator according to a first embodiment.

[0013] As shown in the figure, refrigerator body 10 of refrigerator 1 is open at the front and has storage compartments arranged in this order from the top: refrigerator compartment 2, ice-making compartment 3 arranged side by side on the left and right, upper freezer compartment 4, lower freezer compartment 5, and vegetable compartment 6. Hereinafter, ice-making compartment 3, upper freezer compartment 4, and lower freezer compartment 5 will be collectively referred to as freezer compartment 7.

[0014] The front opening of the refrigerator compartment 2 is opened and closed by rotating refrigerator compartment doors 50a and 50b, which are divided into left and right halves. The front openings of the ice making compartment 3, upper freezer compartment 4, lower freezer compartment 5, and vegetable compartment 6 are opened and closed by drawer-type ice making compartment door 60, upper freezer compartment door 70, lower freezer compartment door 80, and vegetable compartment door 90, respectively. Each of these drawer-type doors is equipped with a drawer container. An opaque resin material can be used for the drawer container. Door hinges (not shown) are provided at the top and bottom of the refrigerator compartment 2. The upper door hinge is covered by a door hinge cover 16.

[0015] The refrigerator compartment 2 is separated from the ice making compartment 3 and the upper freezer compartment 4 by an insulating partition wall 28. The lower freezer compartment 5 and the vegetable compartment 6 are separated by an insulating partition wall 29. An insulating partition wall 30 is disposed on the front side between the ice making compartment 3 and the upper freezer compartment 4 and the lower freezer compartment 5. The insulating partition wall 30 seals the gap between the bottom surfaces of the ice making compartment door 60 and the upper freezer compartment door 70 and the top surface of the lower freezer compartment door 80, preventing air from circulating inside and outside the refrigerator. An insulating partition wall 31 is disposed between the ice making compartment door 60 and the upper freezer compartment door 70. The insulating partition wall 31 seals the gap between the ice making compartment door 60 and the upper freezer compartment door 70, preventing air from circulating inside and outside the refrigerator. Additionally, a heat insulating partition wall 36 is rotatably attached to the inside of refrigerator compartment door 50a on the refrigerator compartment door 50b side (the right-hand side in FIG. 1 ). Heat insulating partition wall 36 closes the gap that occurs between refrigerator compartment doors 50a and 50b when refrigerator compartment doors 50a and 50b are closed, thereby preventing air from circulating between the inside and outside of the refrigerator.

[0016] FIG. 2 is a partial front view showing the interior of the refrigerator of this embodiment.

[0017] As shown in this figure, a space surrounded by an inner box 210 and refrigerator compartment doors 50a and 50b of FIG. 1 is provided inside refrigerator body 10, and a cold air duct panel 220, a food shelf 230, an ice-making water container 240, and a chilled compartment 250 are arranged therein. The exterior of refrigerator 1 is configured by an outer box 300 made of metal such as steel plate. An insulating material such as foam insulating material or vacuum insulating material is provided between inner box 210 and outer box 300. Inner box curved surface portion 210a and inner box protrusion portion 210c are part of inner box 210. Inner box curved surface portion 210a is exposed above cold air duct panel 220. Inner box protrusion portion 210c supports both ends of food shelf 230.

[0018] Inner box curved surface portion 210b shown in Fig. 5 (described later) is covered with cold air duct panel 220. Therefore, it can be said that at least inner box curved surface portion 210b is covered with cold air duct panel 220. Because inner box curved surface portion 210b is located at a height that makes it easily visible to the user, cold air duct panel 220 in Fig. 2 can effectively prevent a decrease in design due to the provision of a recycled resin layer on inner box 210.

[0019] It should be noted that the items placed on food shelf 230 are not limited to food, and food shelf 230 may simply be called a "shelf."

[0020] FIG. 3 is a partial perspective view showing the interior of the refrigerator of this embodiment.

[0021] In this figure, the same configuration as in FIG. 2 is shown from a different angle.

[0022] FIG. 4 is a partial front view showing the refrigerator 1 of FIG. 2 with the food shelf removed.

[0023] 4, the cold air passage panel 220 is an integral part that covers the inner wall surface of the inner box 210. The cold air passage panel 220 has four cold air openings. The inner box 210 has an inner box protrusion 210c.

[0024] FIG. 5 is a cross-sectional view showing the interior of the refrigerator 1 of FIG.

[0025] 5 shows chilled shelf 510 that covers the top of ice-making water container 240 and chilled compartment 250 in FIG. 4, and heat-insulating partition wall 28 that forms the bottom of refrigerating compartment 2. Also shown are legs 520 located at the bottom of refrigerator body 10 (outside the refrigerator). Inner box 210 has inner box curved surface portion 210b.

[0026] FIG. 6 is a partial front view showing the refrigerator of FIG. 4 with the cold air passage panel 220 removed.

[0027] As shown in Fig. 6, inner box 210 has inner box curved portions 210a and 210b, inner box convex portion 210c, and inner box vertex portion 210d. Inner box curved portion 210a is a curved portion connecting the rear surface and top surface of the inner box. Inner box curved portion 210b is a curved portion connecting the rear surface and side surface of the inner box. Inner box vertex portion 210d is a curved portion connecting inner box curved portion 210a and inner box curved portion 210b.

[0028] FIG. 7 is a schematic cross-sectional view showing a resin member formed into two layers by vacuum molding.

[0029] In this figure, resin member 710 is composed of a recycled resin layer 712 and a virgin resin layer 714. Curved surface portion 710b is the curved portion and corresponds to inner box curved surfaces 210a, 210b and inner box vertex 210d of inner box 210 in Figure 6. Flat surface portion 710a is the other portion, which is a flat portion.

[0030] When manufacturing the inner box 210 of the refrigerator 1 of this embodiment, first, a flat laminated resin member is formed by two-layer molding using recycled resin material and virgin resin material. Then, the obtained flat laminated resin member is deformed into the shape of the inner box by vacuum forming.

[0031] In this specification, "recycled resin material" refers to a resin material containing recycled resin, for example, a resin material containing 20% ​​or more, preferably 50% or more, and most preferably 100% by weight of recycled resin. Furthermore, "virgin resin material" refers to a resin material containing a lower proportion of recycled resin than recycled resin materials, for example, less than 20% by weight, preferably 10% or less, and most preferably 0% by weight (unused material that has never been used in a product). When manufacturing a resin member 710 that may come into contact with food, such as the inner box 210, 0% is preferred from the perspective of ensuring hygiene.

[0032] Recycled resin materials may be black, gray, etc. due to the influence of impurities. On the other hand, virgin resin materials can be freely colored and toned.

[0033] When the resin member 710 is used as the inner box 210 of the refrigerator 1, by placing the virgin resin layer 714 on the inside of the refrigerator, the color of the recycled resin layer 712 can be prevented from being recognized when the user looks inside the refrigerator, and the recycled resin can also be prevented from coming into direct contact with food ingredients.

[0034] In curved portion 710b, which is a portion bent by vacuum forming, the resin is stretched, and the thickness of virgin resin layer 714 may become thinner than that of flat portion 710a. In this case, the color of recycled resin layer 712 may be visible through. In inner box curved portions 210a, 210b, inner box convex portion 210c, and inner box vertex 210d of inner box 210 shown in Figure 6, the resin is likely to be stretched during vacuum forming, and the thickness of virgin resin layer 714 is likely to become thinner. Of these, inner box vertex 210d is particularly likely to be stretched and become thinner.

[0035] In this embodiment, the color of the virgin resin layer 714 disposed on the surface of the resin member 710 is selected so that the color difference between the flat surface portion 710a and the curved surface portion 710b is 2.0 or less, preferably 1.5 or less. The virgin resin layer 714 has a higher brightness than the recycled resin layer 712.

[0036] Furthermore, the virgin resin layer 714 or the recycled resin layer 712 preferably contains a pigment in an amount of, for example, 2 to 10 parts by weight per 100 parts by weight of the virgin resin material. A more preferred amount is 3 to 7 parts by weight. Titanium dioxide is a preferred pigment. For example, polypropylene can be used as the virgin resin layer 714.

[0037] Here, the color difference is calculated in accordance with JIS K 5600-4-6:1999 "General test methods for paints - Part 4: Visual properties of coating films - Section 6: Colorimetry (calculation of color difference)" and the lightness is calculated in accordance with JIS Z 8721-1993 "Method of displaying color - Display by three attributes."

[0038] When the color difference is 2.0 or less, preferably 1.5 or less, it is difficult for the user to distinguish the difference in color and the color difference is unlikely to be perceived as unnatural. Furthermore, increasing the brightness of the virgin resin layer 714 is desirable because it makes the color of the recycled resin layer 712 behind it less visible. Adjustments to the color difference and brightness can be achieved, for example, by adjusting the light transmittance and thickness of the recycled resin layer 712 that forms the curved surface portion 710b, or by adjusting the color of the recycled resin layer 712.

[0039] Furthermore, it is desirable to provide a mosaic pattern, marble pattern, or other pattern in which multiple colors are irregularly arranged on the surface of the virgin resin layer 714, because this makes the color of the recycled resin layer 712 less noticeable even if the color of the recycled resin layer 712 shows through. In this case, it is preferable that the color of the irregularly arranged pattern be the same as or similar to the color of the recycled resin layer 712, or include black and / or gray.

[0040] While this embodiment illustrates an inner box 210 formed by vacuum molding, the present invention can also be applied to resin parts formed by a molding method in which the virgin resin layer 714 deforms one or both outermost layers of the plate-shaped resin, resulting in a thinner curved portion (curved surface) compared to other portions, as well as to products incorporating such resin parts, particularly home appliances. As mentioned above, the inner box vertex 210d connecting the two curved surfaces is likely to be thinner than the inner box curved surfaces 210a, 210b connecting the two flat surfaces. Therefore, from a design perspective, it is preferable to design the thickness of the inner box vertex 210d so that it is opaque (e.g., a color difference of 2.0 or less, preferably 1.5 or less, from the flat surfaces). In this case, it is easier to prevent the recycled resin layer 712 from showing through throughout the entire inner box 210.

[0041] Furthermore, it is preferable to make only a portion of the inner box curved surfaces 210a, 210b and the inner box apex 210d opaque and cover the remaining portions with other components, from the perspective of achieving both aesthetic appeal and a thinner inner box wall. For example, the inner box curved surfaces 210a, 210b can be designed to be opaque, while the inner box apex 210d is transparent (e.g., a color difference of more than 2.0 or 1.5 from the flat surfaces). At the same time, the inner box apex 210d can be covered by placing an opaque structure, such as a cold air duct panel 220, on the side of the inner box that the user views (the front side in the case of the refrigerator 1). In this case, the thickness of the inner box 210 can be suppressed, thereby suppressing a decrease in the refrigerator's capacity, while also suppressing the transparency of the recycled resin layer 712. Another example of an opaque structure is the drawer container placed in the vegetable compartment 6 in this embodiment. This drawer container can cover the curved surfaces 210a and 210b of the inner box 210 and the vertex 210d of the inner box 210 at the bottom.

[0042] One method to prevent show-through is to make the thickness of the flat laminated resin member prepared by two-layer molding uneven, i.e., to prepare thicker portions in advance that are expected to become thinner during vacuum molding, etc. In this case, the thickened portions make it difficult for those portions to deform during vacuum molding, and the areas around the thickened portions end up being stretched, making it difficult to reduce the possibility of show-through. For this reason, it is preferable that the thickness of the laminated resin member prepared in advance be uniform.

[0043] (Modification 1) FIG. 8 is a partial front view showing a modification of the cold air passage panel.

[0044] In this figure, as in FIG. 4, the food shelf is removed.

[0045] In Fig. 8, unlike Fig. 4, the upper part of the cold air passage panel 820 covers the inner box curved surface portion 210a of Fig. 4. This prevents the user from noticing the color of the recycled resin used in the inner box curved surface portion 210a even if it is visible through the panel.

[0046] (Modification 2) FIG. 9 is a partial front view showing the interior of a refrigerator according to modification 2. As shown in FIG.

[0047] In this figure, a food shelf 930 is shown installed.

[0048] In Figure 9, support covers 930a are attached to the undersides of both ends of the food shelf 930. This makes the inner box protrusions 210c in Figure 2 less visible to the user. Because the inner box protrusions 210c also include curved portions, their thickness decreases during vacuum molding, which could cause them to become see-through. The support covers 930a prevent the user from noticing the color of the recycled resin used in the inner box protrusions 210c.

[0049] In Figure 9, a support cover 930a is provided on the underside of food shelf 930, but the refrigerator 1 of this modified example is not limited to this configuration. Support covers may be provided on the upper surfaces of both ends of food shelf 930, and food shelf 930 may be installed by hooking the support covers onto the upper surfaces of inner box protrusions 210c, with the support covers also covering the side surfaces of inner box protrusions 210c.

[0050] (Modification 3) FIG. 10 is an exploded perspective view showing a modification of the food shelf.

[0051] In this figure, a cantilever-type food shelf 1011 is used. The food shelf 1011 has a top surface 1013, side surfaces 1014, and hooks 1015. The food shelf 1011 is configured to be fixed by inserting the hooks 1015 into holes 1016 provided in support pillars 1012. The support pillars 1012 consist of a pair of left and right pillars, and are attached in the vertical direction to both the left and right sides of the surface of the cold air passage panel 220 (see FIG. 4) or to both the left and right sides of the back wall of the inner box 210 (see FIG. 6). Refrigerated items such as food can be placed on the top surface 1013.

[0052] By using the food shelf 1011 and support column 1012 shown in this figure, it is not necessary to provide the inner box protrusion 210c shown in Figure 2. This allows the side surface of the inner box 210 to be flat, reducing the area where the thickness of the virgin resin is thin, and preventing the color of the recycled resin from being noticeable to the user.

[0053] 11 is an overall perspective view showing the vacuum cleaner of Example 2. In order to prevent the recycled resin from showing through in this example, the configuration of Example 1 can be adopted as long as it does not cause any problems.

[0054] As shown in the figure, the vacuum cleaner 1100 has a vacuum cleaner main body 1101, a hose joint 1102, a hose 1103, a hand switch 1104 that controls the operation of the vacuum cleaner 1100, an extension tube 1105 connected to the hose 1103, a suction nozzle 1106 that is connected to the extension tube 1105 and sucks in dust from the cleaning surface, and a hand operation unit 1107. The hose 1103 is connected to the vacuum cleaner main body 1101 via the hose joint 1102. The extension tube 1105 has an extendable tube 1105a (zoom pipe). The hand switch 1104 and the hand operation unit 1107 are disposed between the hose 1103 and the extension tube 1105.

[0055] The telescopic tube 1105a has a roughly rectangular cross section with chamfered edges and is produced by blow molding. For such a blow-molded product, it is conceivable to produce a multilayer preform using two-layer extrusion, and then blow-molding it to produce an extension tube. If the telescopic tube 1105a is produced by blow molding in this way, with recycled resin on the inner diameter side and virgin resin on the outer diameter side layered, the resin may be stretched at the corners (curved surfaces) of the roughly rectangular cross section of the telescopic tube 1105a, resulting in a reduction in the thickness of the virgin resin located on the outside. In this case, the color of the recycled resin may be visible through the tube.

[0056] In this embodiment, the color of the virgin resin is selected so that the color difference between the straight edges (flat surfaces) and the corners (curved surfaces) of the approximately rectangular cross section of the expandable tube 1105a is 2.0 or less, preferably 1.5 or less. When the color difference is 2.0 or less, preferably 1.5 or less, users generally cannot distinguish the color difference, preventing the color of the recycled resin placed inside from showing through. It is also desirable to increase the brightness of the virgin resin, as this makes it harder to see the color of the recycled resin in the background.

[0057] Furthermore, it is desirable to provide a pattern such as a mosaic pattern on the surface of the virgin resin, since this makes the color of the recycled resin less visible even if it shows through.

[0058] Furthermore, it is desirable that the outer periphery of the cross section of the telescopic tube 1105a, including the curved and flat portions, i.e., the substantially rectangular cross section of the telescopic tube 1105a, has a longer curved portion than the flat portion. This increases the radius of curvature of the curved portion. The larger the radius of curvature of the curved portion, the more effectively the curved portion is prevented from being stretched during blow molding, maintaining the thickness of the virgin resin layer and preventing the color of the recycled resin placed inside from showing through. Furthermore, a circular cross-sectional shape is most desirable for the telescopic tube 1105a. This is because a circular cross-sectional shape eliminates flat portions, which uniformly applies a force in the circumferential direction of the cross section during blow molding, resulting in a uniform wall thickness of the telescopic tube 1105a.

[0059] In addition to refrigerators and vacuum cleaners, examples of home appliances to which the resin parts of the present disclosure can be applied include washing machines, microwave ovens, and the like.

[0060] Examples of recycled resin and virgin resin materials include polyethylene (PE), polypropylene resin (PP), acrylonitrile butadiene styrene resin (ABS resin), and polyethylene terephthalate resin (PET resin).

[0061] As described above, resin parts manufactured by vacuum forming, blow molding, or the like have a structure in which the resin structure at the curved surface is stretched toward the flat surface of the resin part. Here, the term "resin structure" refers to a fine structure such as the molecular structure of the resin. The resin structure formed by stretching in vacuum forming, blow molding, or the like has a fine structure that can be distinguished from the higher-order structure formed by injection molding.

[0062] The reason why the microstructure of the resin composition differs between vacuum molding, blow molding, etc. and injection molding is as follows.

[0063] In vacuum molding, blow molding, and other processes, a solid resin is heated and softened before being deformed. This causes tension in a specific direction, particularly in curved surfaces, stretching the resin structure and leaving its microstructure intact. In contrast, in injection molding, a fluid resin is injected into a mold and solidified, so the orientation of the molecules that make up the resin is affected by the direction of resin flow within the mold. Therefore, as mentioned above, the resin structure can be distinguished between vacuum molding, blow molding, and injection molding.

[0064] 1: refrigerator, 2: refrigerator compartment, 3: ice maker compartment, 4: upper freezer compartment, 5: lower freezer compartment, 6: vegetable compartment, 7: freezer compartment, 10: refrigerator body, 28, 29, 30, 31, 36: heat insulating partition wall, 210: inner box, 210a, 210b: inner box curved surface portion, 210c: inner box convex portion, 220, 820: cold air duct panel, 230, 930, 1011: food shelf, 240: ice making water container, 250: chilled compartment, 510: chilled shelf board, 520: legs, 7 10: Resin member, 710a: Flat portion, 710b: Curved portion, 712: Recycled resin layer, 714: Virgin resin layer, 930a: Support portion cover, 1012: Support column portion, 1016: Hole, 1015: Hook, 1100: Vacuum cleaner, 1101: Vacuum cleaner body, 1102: Hose fitting, 1103: Hose, 1104: Hand switch, 1105: Extension tube, 1105a: Telescopic tube, 1106: Suction nozzle, 1107: Hand operation unit.

Claims

1. A home appliance comprising a resin part which is a laminated resin member including a recycled resin layer and a virgin resin layer and has a flat portion and a curved portion, the curved portion having a configuration in which the resin structure is stretched toward the flat portion, and the color difference between the curved portion and the flat portion in the virgin resin layer arranged on the surface of the resin part is 2.0 or less.

2. The home appliance according to claim 1, wherein the virgin resin layer contains a pigment.

3. A refrigerator comprising a resin part which is a laminated resin member including a recycled resin layer and a virgin resin layer and has two or more flat portions and a curved portion, wherein the curved portion has a configuration in which the resin structure is stretched toward the flat portions, the curved portion is a portion which connects the two flat portions, the color difference between the curved portion and the flat portions in the virgin resin layer arranged on the surface of the resin part is 2.0 or less in a portion and exceeds 2.0 in the remainder, and a structure is arranged to cover the remainder.

4. A refrigerator comprising a resin part which is a laminated resin member including a recycled resin layer and a virgin resin layer and has a flat portion and a curved portion, the curved portion having a configuration in which the resin structure is stretched toward the flat portion, the resin part being an inner box forming a storage compartment which is open at the front, a cold air duct panel or a pull-out container is arranged in the storage compartment, and at least a portion of the curved portion of the inner box is covered by the cold air duct panel or the pull-out container.

5. A vacuum cleaner comprising a resin part which is a laminated resin member including a recycled resin layer and a virgin resin layer and has a flat portion and a curved portion, the curved portion having a configuration in which the resin structure is stretched toward the flat portion, the resin part being an expandable tube, and the outer periphery of a cross section including the curved portion and the flat portion is longer than that of the flat portion.

6. A refrigerator comprising a resin part which is a laminated resin member including a recycled resin layer and a virgin resin layer and has a flat portion and a curved portion, the curved portion having a configuration in which the resin structure is stretched toward the flat portion, the resin part being an inner box, a shelf being arranged in the inner box, the inner box having an inner box convex portion which is the curved portion, the shelf being supported by the inner box convex portion, the shelf having a support portion cover, and at least the front side of the inner box convex portion being covered by the support portion cover.

Images