Evaporator Casing Protrusion for Foam-Pressure Resistance
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Solution Overview
Problem
The existing evaporator assembly in refrigeration appliances faces challenges during the curing process of foam insulation, where pressure exerted by the curing foam material causes deformation of plastic elements, making it difficult to properly install the evaporator and compromising thermal insulation performance.
Innovation Solution
The evaporator assembly features a detachable casing with a protrusion on the rear cover that withstands foam pressure and has a mounting portion for securing the evaporator, allowing for easy installation and protection from damage during the foaming process, while enabling foam injection after the evaporator is installed, thus simplifying the assembly and maintaining thermal insulation quality.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Stability of the object's composition
If spacers are utilized to prevent deformation of plastic elements during the curing process, then the deformation of plastic elements is prevented, but the assembly process becomes more complicated and thermal insulation performance degrades when foam material is damaged
Solution Approach 1:
The protrusion is pre-formed on the rear cover before the foam material is injected. This preliminary structural feature is designed to withstand the foam pressure during curing, eliminating the need for temporary spacers and simplifying the assembly process while maintaining the stability of plastic elements.
2Loss of energy
If foam material is injected before evaporator installation, then thermal insulation is provided, but the evaporator installation becomes difficult and plastic elements deform under foam pressure
Solution Approach 1:
The evaporator is installed into the casing before the foam material is injected. The protrusion on the rear cover is already in place to provide structural support during foam curing, allowing the evaporator to be positioned correctly first, then the foam is injected to provide thermal insulation without causing deformation.
3Loss of energy
If foam material is injected between rear cover and outer case, then thermal insulation is achieved, but pressure during curing deforms plastic elements and obstructs evaporator installation
Solution Approach 1:
The protrusion is strategically positioned on the rear cover at a location that does not obstruct the evaporator installation path. This localized structural feature provides the necessary strength to withstand foam pressure in critical areas while leaving other areas open for evaporator access and installation, thereby maintaining both thermal insulation and manufacturing precision.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
This solution ensures proper installation of the evaporator without deformation, enhances thermal insulation, and simplifies the manufacturing process by allowing foam injection post-evaporator installation, ensuring high-quality insulation and protection from foam-induced damage.
Implementation Method 1
A cross-section and a material of the protrusion is configured to exhibit a sufficient strength to withstand without being deformed, a pressure exerted by a curing foam material
Implementation Method 2
a region between the inner case of the refrigeration compartment and the outer case of the refrigeration appliance is filled with foam material, in particular polyurethane
Data Source
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AI summary
The present invention relates to an evaporator assembly (1) for use in a refrigeration appliance (2). The evaporator assembly (1) of the present invention has a casing (6) for accommodating an evaporator (7). The casing (6) has on its inner surface (9a) a protrusion (10) abutting against an opposing surface thereof. The protrusion (10) has a sufficient strength to withstand a pressure exerted by a foam material which cures during an assembly process. In addition, the protrusion (10) does not obstruct installation of the evaporator (7) into the casing (6). The present invention also relates to a manufacturing process of a refrigeration appliance (2). The manufacturing process of the present invention comprises a step of installing the evaporator (7) into the casing (6) and a subsequent step of injecting foam material between an outer case (5) of the refrigeration appliance (2) and an outer surface (9b) of the casing (6).