Refrigerator Door Foaming Material Overflow Prevention Assembly
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Solution Overview
Problem
The existing manufacturing process for refrigerator doors involves manual cleaning of foaming material, leading to increased costs and reduced product quality due to incomplete discharge and overflow issues.
Innovation Solution
A door design with a material overflow preventing assembly, featuring an air discharge hole and a material discharging passage that allows foaming material to transition to a cured state within a receiving cavity, preventing overflow and automating air discharge, thus eliminating the need for manual cleaning.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If air discharge hole is used to discharge air after foaming, then air can be discharged from the door, but foaming material overflows through the air discharge hole and requires manual cleaning
Solution Approach 1:
The air discharge hole is segmented into two functional zones: an inner receiving cavity for capturing overflowing foaming material, and an outer discharge channel for air. This segmentation allows the same hole to serve dual purposes while preventing material contamination outside the door.
Solution Approach 2:
The receiving cavity acts as an intermediary structure between the foaming material discharge path and the external environment. It captures and contains the foaming material that overflows during the gelation stage, preventing it from reaching the external surface where manual cleaning would be required.
2Productivity
If foaming material is discharged through air discharge hole, then air can be discharged, but foaming material cannot be cleaned thoroughly affecting product quality
Solution Approach 1:
The overflow of foaming material, which was previously a harmful effect requiring manual cleaning, is converted into a beneficial containment process. The receiving cavity captures the overflowing material, and its cured state provides structural support while eliminating the need for manual cleaning operations.
Solution Approach 2:
The system utilizes the parameter change of foaming material from liquid (during injection) to gel/cured state (during and after foaming). By timing the discharge and utilizing the gelation process, the material transitions to a state where it can be contained and cured in place, eliminating cleaning requirements.
3Manufacturing precision
If material discharging passage is designed with proper projection areas, then foaming material is contained in receiving cavity, but structure becomes more complex
Solution Approach 1:
The door frame structure is designed to serve multiple functions: it provides the structural support for the door, contains the receiving cavity for material containment, and forms the material discharging passage with appropriate projection areas. This multi-functionality reduces the need for additional specialized components.
Solution Approach 2:
The receiving cavity is nested within the door frame structure, utilizing the existing spatial framework. The material discharging passage is integrated into the door frame geometry, with projections that define the passage boundaries. This nesting approach contains the complexity within the existing structural envelope rather than adding separate external components.
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 reduces manufacturing costs and improves product quality by ensuring complete discharge and preventing foaming material overflow, thereby streamlining the process and enhancing the door's manufacturing efficiency.
Implementation Method 1
the foaming material in the gelation state will be discharged through the air discharge hole out of the door end covers
Implementation Method 2
a curing stage
Implementation Method 3
air inside the door needs to be discharged
Data Source
AI summary
The present invention discloses a door for a refrigerator, a refrigerator and a method of manufacturing the door. The door comprises a door frame enclosed at a periphery, and a first side plate and a second side plate located on two opposed sides of the door frame, the door frame, the first side plate and the second side plate forming a receiving space for receiving a foaming material, wherein the door frame is provided with at least one material overflow preventing assembly which comprises an air discharge hole disposed on the door frame, a receiving cavity communicated with the air discharge hole, and a material discharging passage communicated with the receiving cavity, the air discharge hole is communicated with the external, and the material discharging passage is communicated with the receiving space. The present invention makes the manufacturing cost lower and the quality of products of the door higher.