One-Piece Refrigerator Inner Liner with Integrated Freezer Evaporator
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Solution Overview
Problem
The complex manufacturing process of refrigerating apparatuses with a freezer compartment above or below the refrigerator compartment requires a lengthy and intricate inner liner structure due to the need for precise placement and structural support of the wound box evaporator, which is time-consuming and prone to damage.
Innovation Solution
A method involving two distinct forming steps for a polymeric inner liner, interspersed with the mounting of the evaporator portion, allows for a one-piece component construction, where the freezer delimiting shell is thermoformed first, followed by wrapping the evaporator pipe around it, and then forming the refrigerator delimiting shell, using connection elements and interposing materials for secure attachment.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a wound box evaporator is used to surround the freezer compartment for even heat transfer, then freezing efficiency is improved, but the manufacturing process becomes complex and time-consuming due to precise placement requirements
Solution Approach 1:
The evaporator is integrated into the inner liner structure itself, merging two previously separate components (evaporator and inner liner) into a single unified structure. This eliminates the need for separate placement and securing operations, thereby improving manufacturing speed while maintaining freezing efficiency.
Solution Approach 2:
The evaporator channels are pre-formed within the inner liner structure during the molding process, rather than being installed separately afterward. This preliminary integration simplifies the manufacturing process and reduces assembly complexity, directly addressing the productivity issue.
2Reliability
If the evaporator is securely attached to the inner liner, then reliability of heat transfer is improved, but the inner liner structure becomes more complex
Solution Approach 1:
By combining the evaporator and inner liner into a single integrated component, the patent eliminates the need for separate attachment mechanisms. The evaporator channels become an inherent part of the inner liner structure, reducing overall structural complexity while ensuring reliable heat transfer.
Solution Approach 2:
The inner liner is formed as a composite structure incorporating both the liner material and the evaporator channels within a single molded component. This composite approach simplifies the overall structure by eliminating the need for separate attachment systems while maintaining reliable thermal contact.
3Adaptability or versatility
If multiple parts are assembled to form the inner liner, then adaptability of the structure is improved, but the manufacturing time increases
Solution Approach 1:
The patent merges multiple inner liner parts into a single molded component that integrates the evaporator structure. This one-piece construction eliminates assembly steps and reduces manufacturing time while maintaining the structural adaptability needed for different evaporator configurations.
Solution Approach 2:
The integrated inner liner structure serves multiple functions simultaneously: it provides the thermal insulation barrier, structural support, and evaporator mounting. This multi-functionality is achieved through a single component design, reducing manufacturing complexity and time while maintaining adaptability.
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 approach simplifies the manufacturing process, reduces the risk of damage, and results in a faster, more reliable production of refrigerating apparatuses with a seamless one-piece inner liner, enhancing both efficiency and aesthetic appeal.
Implementation Method 1
forming a freezer delimiting shell in a precursor element of the inner liner... forming a refrigerator delimiting shell in the precursor element adjacent to the freezer delimiting shell
Data Source
Figure 1
Figure 2A~2B
Figure 2C~2D
AI summary
A method for manufacturing a refrigerating apparatus (100) is proposed. The method comprising the step of providing an inner liner (125) adapted to define a refrigerator compartment (110a) for storing goods to be cooled and a freezer compartment (110b) for storing goods to be frozen, the inner liner being provided as a one-piece component part. In a solution according to an embodiment of the invention, the step of providing the inner liner comprises forming a freezer delimiting shell (125b) in a precursor element (200) of the inner liner (125), providing an evaporator portion (130) around the freezer delimiting shell (125b), and forming a refrigerator delimiting shell (125a) in the precursor element (200) adjacent to the freezer delimiting shell (125b) with the evaporator portion (130).