Integrated Refrigerator Door Assembly for Sealing and Insulation
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Solution Overview
Problem
The manufacturing process of refrigerator doors is complex, labor-intensive, and prone to errors and waste due to the need for multiple components and assembly steps, which complicates the achievement of hermetic sealing and thermal insulation while also requiring decorative finishes.
Innovation Solution
A method involving a door body with integral sections and a door lining, where polyurethane foam is poured between the sections to provide insulation and secure the assembly, reducing the number of parts and assembly steps, and allowing for the use of durable plastic or decorative materials that eliminate post-processing for logos and finishes.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If multiple components and assembly steps are used to achieve hermetic sealing and thermal insulation, then the sealing and insulation functions are improved, but the manufacturing complexity and labor intensity increase
Solution Approach 1:
The patent combines multiple functions (structural support, thermal insulation, hermetic sealing, and decorative finish) into a single integrated door panel. The door body is formed as one piece with integral flanges that simultaneously provide structural support and sealing surfaces, eliminating the need for separate components and assembly steps while maintaining all required functions.
Solution Approach 2:
The door body is designed as a multi-functional component that simultaneously serves as the structural frame, insulation carrier, sealing element, and decorative surface. The integral flanges perform multiple roles including structural reinforcement, gasket mounting, and sealing functions, reducing the total number of parts needed.
2Reliability
If multiple components and assembly steps are used, then the insulation and sealing functions are improved, but the labor intensity and production cost increase
Solution Approach 1:
The patent combines multiple functions (structural support, thermal insulation, hermetic sealing, and decorative finish) into a single integrated door panel. The door body is formed as one piece with integral flanges that simultaneously provide structural support and sealing surfaces, eliminating the need for separate components and assembly steps while maintaining all required functions.
3Reliability
If separate components are assembled, then the insulation and sealing functions are achieved, but the number of parts and assembly steps increase
Solution Approach 1:
The patent combines multiple functions (structural support, thermal insulation, hermetic sealing, and decorative finish) into a single integrated door panel. The door body is formed as one piece with integral flanges that simultaneously provide structural support and sealing surfaces, eliminating the need for separate components and assembly steps while maintaining all required functions.
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 simplifies the manufacturing process, reduces waste and errors, and enables cost-effective production of refrigerator doors with different sizes and appearances, while ensuring high thermal insulation and durability.
Implementation Method 1
The liquid foam material which is poured into the inner side of the door body completely fills the gap enclosed by the door body and the door lining. The polyurethane filled between the door lining and the door body provides a relatively high thermal insulation
Implementation Method 2
The assembly process of door body and the door lining is completed when the polyurethane is totally cured. The polyurethane filled between the door lining and the door body firmly joins the door lining and the door body together
Data Source
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AI summary
The present invention relates to a method of manufacturing a refrigerator door (1). The method of manufacturing the refrigerator door (1) according to the present invention comprises a step of providing a door body (2) which has an upper section (3a), a lower section (3b), a left lateral section (3c), a right lateral section (3d), and a body section (3e), wherein each of the upper section (3a), the lower section (3b), the left lateral section (3c), and the right lateral section (3d) has an outer flange portion (3f) which projects vertically away from an inner side of the door body (2) so as to enclose a space for retaining foam material.