Injection-Molded Refrigerator Inner Case Assembly for Compact Storage
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Solution Overview
Problem
The existing methods for manufacturing refrigerator inner cases are limited by the vacuum forming method, which restricts the types, thickness, and load-bearing capabilities of materials, particularly when attaching metal plates, and do not efficiently utilize space for storage and transportation.
Innovation Solution
The refrigerator inner case is assembled from injection-molded plates (upper, lower, left, and right) with integrated features such as flanges, protrusions, and concave portions for assembly, allowing for modular construction, efficient use of space, and integration of components like evaporators and heat insulating materials, while also enabling the formation of separate refrigerating and freezing compartments.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If the vacuum forming method is used to manufacture inner cases, then resin materials can be formed, but the types, thickness, and load-bearing capabilities of materials are restricted
Solution Approach 1:
The inner case is divided into multiple separate plates (front plate, rear plate, left plate, right plate, upper plate, lower plate) that can be manufactured independently using injection molding. This segmentation allows each plate to be optimized for specific material properties and thickness requirements, overcoming the limitations of vacuum forming while maintaining manufacturing efficiency.
Solution Approach 2:
The invention uses injection-molded plates that can be made from diverse materials including metals and composite materials, not limited to resin materials. This allows for greater material versatility and load-bearing capabilities while maintaining ease of manufacture through standardized injection molding processes.
2Strength
If metal plates are attached to the inside of the inner case, then load-bearing capability is improved, but the type and thickness of bondable materials are restricted
Solution Approach 1:
Instead of attaching metal plates separately, the invention integrates metal plates directly into the inner case structure through injection molding. The metal plates and resin plates are combined into a unified structure where the metal plates form integral parts of the inner case, eliminating the need for separate bonding processes and expanding material options.
Solution Approach 2:
The invention creates composite structures by combining metal plates with resin plates through injection molding. This allows for versatile material combinations including metal-resin composites, enabling both improved load-bearing capability and greater material versatility without being restricted by bonding constraints.
3Volume of moving object
If the inner case is assembled from multiple injection-molded plates, then space utilization during storage and transportation is improved, but the assembly complexity increases
Solution Approach 1:
The inner case is segmented into multiple plates that can be collapsed or nested during storage and transportation, significantly reducing the volume occupied. Each plate can be independently positioned to maximize space utilization while maintaining structural integrity when assembled.
Solution Approach 2:
The multiple plates are designed with standardized connection features that allow them to be assembled in various configurations. The same set of plates can form different inner case shapes and sizes, providing multi-functionality that reduces assembly complexity despite the modular design.
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 modular design reduces the volume of refrigerators during storage and transportation, allowing more units to be stored and transported in a smaller space, thereby lowering logistics and transportation costs while maintaining effective insulation and compartment functionality.
Implementation Method 1
a heat insulating material disposed between the inner case and the outer case
Data Source
AI summary
A refrigerator includes: an inner case as assembled by a plurality of plates including an upper plate, a lower plate, a left plate, a right plate, and a rear plate, configured so that, while they are assembled with each other, form a storage compartment. At least one among the plurality of plate is injection molded. The refrigerator also includes an outer case configured to be coupleable to an outside of the inner case to form an external appearance; and a heat insulating material disposed between the inner case and the outer case. The at least one injection molded plate among the upper plate, the lower plate, the left plate, and the right plate includes a front flange integrally formed at a front side of the at least one injection molded plate, and the outer case is configured to be coupleable to the front flange.