Integrated Refrigerator Door Liner Hinge Pins to Prevent Foam Leaks
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Solution Overview
Problem
Refrigerator door hinge pin assemblies require complex assembly of multiple parts, leading to issues like leaks, misalignment, and increased costs due to separate design, tooling, and storage, as well as the need for additional holes that create leak points during foam insulation.
Innovation Solution
An injection-molded door liner with integrally formed upper and lower hinge assemblies simplifies assembly, reduces parts, and minimizes leaks by defining the hinge pins within a single, integral piece, eliminating the need for complex assembly and additional parts.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If a metal hinge pin assembly with multiple separate parts is used, then the hinge assembly can be assembled and painted before attachment, but it requires separate design, tooling, procurement, and storage, increasing device complexity and cost
Solution Approach 1:
The hinge pin assembly is merged with the door liner by integrating the hinge pin directly into the molded door liner structure. This eliminates the need for separate metal hinge brackets and pins, reducing the number of parts while maintaining the assembly functionality. The hinge pin becomes an inherent feature of the door liner rather than a separate component requiring assembly.
2Reliability
If four holes are drilled in the door liner for screw attachment, then the hinge bracket can be securely attached, but it creates leak points during the foam insulation process
Solution Approach 1:
The harmful feature of requiring multiple attachment holes is eliminated by taking out the traditional screw-attachment method. Instead, the hinge pin is integrated directly into the door liner molding process, requiring no holes to be drilled or screws to be inserted. This extraction of the attachment function from the insulation process eliminates the source of foam leaks while maintaining secure hinge attachment.
3Ease of manufacture
If a complex hinge pin assembly with multiple parts is used, then the hinge can be assembled before painting, but it increases the likelihood of misalignment or improper installation
Solution Approach 1:
The hinge pin is pre-formed as an integral part of the door liner during the molding process, rather than being assembled from separate components. This preliminary formation ensures precise alignment is built into the structure itself, eliminating the need for subsequent alignment adjustments or precision assembly operations. The hinge pin emerges from the molding process already in its correct position and orientation.
Data Source
AI summary
An injection-molded door liner for a refrigerator door is provided. The door liner is injection molded as a single, integral piece and defines an icebox compartment, an upper hinge assembly, and a lower hinge assembly. An icebox door is rotatably mounted to the upper and lower hinge assembly to insulate the icebox compartment from the fresh food chamber. In this manner, the icebox compartment and the icebox door define a sealed chamber for receiving chilled air from a sealed cooling system.