Refrigerator with a composite outer structure including metal

Abstract

Refrigerator having one or more refrigeration compartments for storing goods. The refrigerator also has a composite outer structure surrounding the refrigeration compartment, and the composite outer structure has an outer most layer composed of metal, and an inner layer composed of material distinct from the outer layer bonded to the outer most layer. The outer most layer has a thickness no greater than 0.5mm.

Description

Attorney Docket No. 4623BV-000263-WO-POAREFRIGERATOR WITH A COMPOSITE OUTER STRUCTURE INCLUDING METAL AND CARDBOARDCROSS-REFERENCE TO RELATED APPLICATIONS

[0001] This application claims the benefit of U.S. Provisional Application No. 63 / 700,806, filed on September 30, 2024. The entire disclosure of the above application is incorporated herein by reference.FIELD

[0002] The present disclosure relates generally to refrigerators. More particularly, the present disclosure relates to a refrigerator including a composite outer structure including a metal layer and a cardboard layer.BACKGROUND

[0003] This section merely provides background information related to the present disclosure and may not constitute prior art.

[0004] Vehicles, including but not limited to recreational vehicles ("RVs" in the United States, "Caravans" and "Campers" in Europe), tractor trailers, airplanes, boats, trains, and the like, often incorporate refrigeration systems for the comfort and convenience of the occupants. Refrigerators designed for these mobile applications must account for space constraints, weight limitations, and power efficiency.

[0005] Traditionally, such refrigerators have included an outer shell constructed of a single-layer steel structure. While steel provides durability and resistance to impact, it is also relatively heavy, which can affect fuel consumption and overall vehicle performance, especially in weight-sensitive environments.

[0006] While prior refrigerator designs have been generally suitable for their intended purposes, continuous improvements in the relevant art are desired, particularly to reduce weight and enhance manufacturing efficiency without compromising the structural integrity of the refrigerator's outer shell.SUMMARY

[0007] This section provides a general summary of the disclosure, and is not a comprehensive disclosure of its full scope or all of its features.Attorney Docket No. 4623BV-000263-WO-POA

[0008] It is a general object of the present teachings to provide a refrigerator for mobile applications incorporating a composite outer shell that reduces weight without compromising durability.

[0009] It is another general object of the present teachings to provide a refrigerator construction that utilizes a multi-layer outer structure to achieve material and cost savings.

[0010] It is another general object of the present teachings to improve the manufacturability of mobile refrigerators by simplifying the formation of the outer shell.

[0011] According to one particular aspect of the present teachings, a refrigerator is provided including one or more refrigeration compartments for storing goods and a composite outer structure surrounding the refrigeration compartments. The composite outer structure includes an outer-most layer composed of metal, and an inner layer distinct from the outer-most layer. The inner layer is bonded to the outer-most layer, which has a thickness no greater than 0.5mm. In certain applications the thickness of the outermost layer is no greater than 0.25mm. In other applications, the thickness of the outermost later is no greater than 0.2mm. The composite outer structure is configured to reduce the weight of the refrigerator while maintaining the necessary structural integrity.

[0012] According to another particular aspect of the present teachings, a method is provided for forming a composite outer structure for a refrigerator. The method includes providing an outer-most layer composed of metal with a thickness no greater than 0.5mm, providing an inner layer distinct from the outer-most layer, bonding the inner layer to the outer-most layer using an adhesive, and shaping the composite outer structure to surround one or more refrigeration compartments. The method facilitates the construction of a lightweight yet durable refrigerator suitable for mobile applications.

[0013] Further areas of applicability will become apparent from the description provided herein. The description and specific examples in this summary are intended for purposes of illustration only and are not intended to limit the scope of the present disclosure.DRAWINGS

[0014] The present teachings will become more fully understood from the detailed description, any appended claims and the following drawings. The drawings are for illustrative purposes only and are not intended to limit the scope of the present disclosure.Attorney Docket No. 4623BV-OOQ263-WO-POA

[0015] FIG. 1 is a perspective view of a refrigerator constructed in accordance with the present teachings.

[0016] FIG. 2 is a simplified sectional view illustrating the construction of an outer composite structure of the refrigerator of FIG. 1 .DETAILED DESCRIPTION

[0017] The following description is merely exemplary in nature and is not intended to limit the present disclosure, its application, or uses. It will be understood that throughout the drawings, corresponding reference numerals indicate like or corresponding parts and features.

[0018] With general reference to the drawings, a refrigerator constructed in accordance with the present teachings is shown. The term “refrigerator” will be understood to mean a cooling device designed to preserve perishable goods. While a particular embodiment of the refrigerator is depicted in the drawings, it will be understood that the various features of the present teachings are not limited to this specific embodiment. In this regard, the features of the present teachings may be adapted individually or in any combination for a variety of refrigerator designs and applications.

[0019] In one particular application, the refrigerator is intended for use within mobile environments such as recreational vehicles (RVs), boats, airplanes, and other transportable settings. After a review of the remainder of this detailed description, those skilled in the art will readily appreciate that the present teachings are not limited to such mobile applications. Rather, various aspects of the present teachings have applicability to other environments.

[0020] A refrigerator constructed in accordance with the present teachings features a composite outer structure designed to enhance performance in mobile environments. The refrigerator includes one or more refrigeration compartments for the storage of perishable goods. Surrounding these compartments is a composite outer structure that provides both durability and weight reduction.

[0021] The composite outer structure comprises an outer-most layer made of metal. This metal layer may be constructed of steel and is specifically designed to have a thickness no greater than 0.5mm. In certain applications the thickness of the outermost layer is no greater than 0.25mm. In other applications, the thickness of the outermost later is no greater than 0.2mm. The thin metal layer contributes to a significant reduction in overall weight, which is crucial for mobile applications where weight constraints are aAttorney Docket No. 4623BV-OOQ263-WO-POA major concern. The outer-most metal layer is bonded to an inner layer using an adhesive. The inner layer is composed of a material distinct from the metal layer, such as cardboard or other lightweight materials, which further aids in reducing the weight of the refrigerator while maintaining structural integrity.

[0022] In one embodiment, the metal layer is chosen for its strength and durability, ensuring that the refrigerator is able to withstand the rigors of transport and use in mobile environments. The choice of the inner layer material is made to complement the outer-most metal layer in terms of weight reduction and manufacturing efficiency. The adhesive used for bonding is selected to provide a strong and lasting connection between the metal and inner layers, ensuring the composite outer structure remains intact under varying conditions. The outer-most metal layer may be constructed of steel or aluminum, for example.

[0023] The method of forming this composite outer structure involves several steps. First, an outer-most layer composed of metal with a thickness no greater than 0.5mm is provided. Again, the outermost metal layer may be constructed of steel or aluminum. This thin metal layer is prepared to meet the structural and weight requirements of the refrigerator. Next, an inner layer made of a material distinct from the metal layer is provided. This inner layer may be constructed from lightweight materials like cardboard, which contribute to further weight savings.

[0024] The method then involves bonding the inner layer to the outer-most metal layer using an adhesive. The adhesive is chosen to ensure a robust bond that can withstand the conditions encountered during use. Once the layers are bonded, the composite outer structure is shaped to surround one or more refrigeration compartments. This shaping process is designed to fit the composite structure around the refrigeration compartments precisely, ensuring an efficient and effective assembly.

[0025] Overall, the described composite outer structure and method offer significant advantages in terms of weight reduction, material efficiency, and ease of manufacture. These features make the refrigerator particularly suitable for use in mobile applications where weight and durability are key considerations.

[0026] While one or more specific examples have been discussed in the specification and illustrated in the drawings, it will be understood by those skilled in the art that various changes may be made and equivalence may be substituted for elements thereof without departing from the scope of the present teachings. For example, while the present teachings have been described in connection with a refrigerator for a vehicle,Attorney Docket No. 4623BV-OOQ263-WO-POA the invention is not so limited and may be extended to other applications. Moreover, many modifications may be made to adapt a particular situation or material to the present teachings without departing from the essential scope thereof. Therefore, it may be intended that the present teachings not be limited to the particular examples illustrated by the drawings and discussed in the specification as the best mode of presently contemplated for carrying out the present teachings but that the scope of the present disclosure will include any embodiments following within the foregoing description and any appended claims.

Claims

Attorney Docket No. 4623BV-OOQ263-WO-POACLAIMSWhat is claimed is:1 . A refrigerator comprising: one or more refrigeration compartments for the storing of goods; and a composite outer structure surrounding the refrigeration compartment, the composite outer structure including: i. an outer-most layer composed of metal; ii. an inner layer composed of a material distinct from the outer layer, wherein the intermediate layer is bonded to the outer-most layer; wherein the outer-most layer has a thickness no greater than 0.5mm.

2. The refrigerator of claim 1 , wherein the inner layer is constructed of cardboard.

3. The refrigerator of claim 1 , wherein the outer-most layer has a thickness no greater than 0.25mm.

4. The refrigerator of claim 1 , wherein the outer-most layer has a thickness no greater than 0.2mm.

5. The refrigerator of claim 1 , wherein the outer-most layer is constructed of steel.

6. The refrigerator of claim 1 , wherein the outer-most layer is constructed of aluminum.

7. A method of forming a composite outer structure for a refrigerator comprising: providing an outer-most layer composed of metal with a thickness no greater than 0.5mm; providing an inner layer composed of a material distinct from the outer-most layer;Attorney Docket No. 4623BV-000263-WO-POA bonding the inner layer to the outer-most layer using an adhesive; and shaping the composite outer structure to surround one or more refrigeration compartments.

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