Refrigerator Door Ramp Structure to Reduce Front Panel Damage
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Solution Overview
Problem
During the manufacturing of refrigerator doors with glass, ceramic, or resin front panels, manufacturing deviations can cause the panels to be pressed on a ramp, leading to damage and scrapping, especially when the panels are installed over a concave portion with a ramp.
Innovation Solution
A detachable member isolated from the thermal insulation material is used to form part of the ramp, allowing it to be assembled after the front panel is connected, reducing the likelihood of the panel being pressed on the ramp and facilitating manufacturing processes for both panels with and without the front panel.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If the ramp is integrated into the door housing with thermal insulation material, then the structural strength is improved, but the front panel may be pressed on the ramp during manufacturing causing damage
Solution Approach 1:
The ramp structure is segmented into two parts: a fixed base portion integrated into the door housing and a detachable member that can be assembled separately. This allows the front panel to be installed first without the complete ramp structure, eliminating the pressing risk while maintaining structural strength when the detachable member is assembled.
Solution Approach 2:
The front panel is installed on the door housing before the detachable member forming the ramp is assembled. This preliminary installation sequence ensures that the panel is already in position when the ramp structure is completed, preventing any pressing damage during the ramp assembly process.
2Object-affected harmful factors
If the ramp is formed by a detachable member assembled after thermal insulation injection, then the front panel damage risk is reduced, but the manufacturing process complexity increases
Solution Approach 1:
The ramp is divided into a fixed base portion and a detachable member, allowing separate manufacturing and assembly. The detachable member can be pre-formed and then assembled to the door housing after thermal insulation injection, reducing process complexity compared to forming the complete ramp structure before insulation.
Solution Approach 2:
The ramp structure transitions from a static integrated design to a dynamic assembly where the detachable member can be added at different stages. This flexibility allows manufacturers to choose the optimal assembly timing based on production requirements, balancing complexity and damage prevention.
3Adaptability or versatility
If the detachable member forms the ramp after front panel installation, then manufacturing flexibility is improved, but the number of assembly steps increases
Solution Approach 1:
The detachable member assembly timing is made flexible and adaptable to different manufacturing scenarios. Manufacturers can assemble the detachable member at the optimal time based on production flow requirements, whether immediately after insulation injection or later, allowing customization of the manufacturing process to reduce overall assembly time.
Solution Approach 2:
The detachable member serves multiple functions: it forms the ramp structure, provides a connection interface for the front panel, and can be assembled at different stages of manufacturing. This multi-functionality reduces the need for additional specialized components, offsetting the increased assembly steps with design efficiency.
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 prevents damage to the front panel by reducing the height of the ramp when the detachable member is not assembled, allowing for accurate positioning and uniform gaps, thus enhancing manufacturing efficiency and reducing panel scrap rates.
Implementation Method 1
a door housing, which is provided with a thermal insulation material therein, where the thermal insulation material is combined with the door housing
Data Source
AI summary
A door for a refrigerator includes a door housing, which is provided with a thermal insulation material therein, where the thermal insulation material is combined with the door housing. The door housing has a concave portion recessed backwards from a front surface of the door, where one end of the concave portion is provided with a ramp that extends forwards. A detachable member is provided and is isolated from the thermal insulation material and is connected to the door housing. Accordingly, at least one part of the ramp is formed by the detachable member.