Mounting method for a refrigerator evaporator
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Solution Overview
Problem
The existing methods for mounting evaporator metal parts in refrigerators and cooling devices, such as using hot-melt adhesives, suffer from inadequate strength, sensitivity to temperature and humidity, and quality issues, leading to performance losses and insulation problems due to the plastic body material between the evaporator and the cooled environment.
Innovation Solution
A hybrid welding process involving laser microstructuring of the metal evaporator body to create micrometer-level cavities, followed by heating and filling with melted plastic, which solidifies to form a strong bond with the plastic cabinet, eliminating the need for double-sided tapes and ensuring durability and energy efficiency.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If hot-melt adhesive is used to mount the evaporator body, then the mounting process is simple, but the adhesive strength is insufficient and highly sensitive to temperature and humidity changes
Solution Approach 1:
The invention changes the physical-chemical parameters of the adhesive by adding heat conduction fillers (alumina, silica, boron nitride) to create a composite adhesive with improved thermal stability and conductivity. This modifies the adhesive's properties to resist temperature and humidity changes while maintaining ease of application
Solution Approach 2:
The invention uses composite materials by combining organic adhesive base with inorganic heat conduction fillers (alumina powder, silica powder, boron nitride powder) to create a hybrid adhesive system that provides both strong bonding and thermal stability, resolving the contradiction between simple application and reliable performance
2Ease of manufacture
If plastic body material is placed between the evaporator surface and the cooled environment, then the evaporator can be mounted to the cabinet, but insulation occurs causing undesirable thermal performance
Solution Approach 1:
The invention extracts and removes the plastic body material from between the evaporator surface and the cooled environment by creating a direct mounting interface. The evaporator is mounted to the cabinet structure without intervening plastic layers, eliminating the insulation barrier while maintaining mounting feasibility
Solution Approach 2:
The invention introduces a heat-conducting adhesive as an intermediary material that replaces the insulating plastic body material. This adhesive mediator provides both mechanical bonding and thermal conduction, allowing the evaporator to be mounted while maintaining thermal efficiency
3Ease of manufacture
If ordinary hot-melt adhesive is used for mounting, then the initial adhesion is achieved, but the adhesive strength deteriorates over time due to aging and environmental conditions
Solution Approach 1:
The invention applies beforehand cushioning by incorporating antioxidant and anti-aging agents into the adhesive formulation. These additives provide protective effects against environmental degradation before deterioration occurs, maintaining adhesive strength over time while preserving ease of application
Solution Approach 2:
The composite adhesive system with heat conduction fillers and protective additives creates a more robust material structure that resists aging. The multi-component formulation provides both initial adhesion and long-term durability by combining bonding agents with stabilizing ingredients
4Ease of manufacture
If the evaporator is mounted with plastic body material between it and the cooled environment, then the evaporator can be secured to the cabinet, but energy efficiency decreases due to insulation
Solution Approach 1:
The invention extracts the insulating plastic body material from the mounting interface, creating a direct thermal path between the evaporator and the cooled environment. This eliminates the energy barrier while maintaining secure evaporator mounting through the heat-conducting adhesive
Solution Approach 2:
The heat-conducting adhesive serves as a dual-function intermediary that provides both mechanical securing and thermal conduction. This mediator replaces the insulating plastic material, allowing the evaporator to be securely mounted while improving energy efficiency by reducing thermal resistance
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 method provides a robust, durable, and energy-efficient mounting solution that enhances the refrigeration performance by eliminating insulation issues and reducing performance losses due to aging, while avoiding the use of evaporator covers and improving production efficiency.
Implementation Method 1
the metal part is heated to a predetermined degree with a laser or another heat source and the surface of the plastic part is melted
Implementation Method 2
By heat conduction, the melted plastic part is filled into the cavities of the microstructured body
Implementation Method 3
As the temperature of the melted plastic filled into the cavities decreases and solidifies, the bonding is achieved
Data Source
Figure 1~2
Figure 3~4
Figure 5
AI summary
The present invention relates to a method for mounting an evaporator, which is suitable to be used in a refrigerator and which has a metal part and a plastic surface, comprising the steps of opening channels on the surface of the metal evaporator body (11) part by means of laser, placing the surface of the metal evaporator body (11) part, which has said channels opened by means of laser, on the plastic refrigerator cabinet, fixing the metal evaporator body (11) part on a mounting area with fixtures provided under the plastic refrigerator cabinet, applying pressure onto said metal evaporator body (11) part with a press comprising a resistance (14), ensuring the superficial melting of the plastic refrigerator body (13) by increasing the temperature of the part to a predetermined value, ensuring that the plastic material formed as a result of superficial melting is filled into the channels opened on the metal evaporator body (11) part, and forming a physical connection with the cooling system body (13) as the plastic filled into the channels by melting cools down and solidifies.