Steel Refrigerator Door Assembly With Hidden Laser-Welded Frame
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Solution Overview
Problem
The manufacturing process of refrigerator doors lacks efficiency and strength, with existing methods failing to maintain fixation strength and aesthetic appeal while simplifying assembly processes.
Innovation Solution
A refrigerator door design featuring a steel frame, support portion, and coupling member with zinc galvanized steel components, utilizing laser welding and press processes to enhance structural integrity and aesthetic appeal, and a manufacturing method that includes press-working, welding, and injecting liquid-foam for insulation and assembly.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If traditional manufacturing methods are used for refrigerator doors, then the assembly process is complex and productivity is low, but the manufacturing precision and structural integrity are maintained
Solution Approach 1:
The patent merges multiple manufacturing operations into integrated processes. The press process simultaneously forms the frame, support portion, and coupling member with built-in projections, eliminating separate machining steps. Laser welding combines heating and joining functions in one operation, and liquid foam injection integrates insulation and structural bonding in a single step, thereby simplifying the overall assembly process and improving productivity
2Strength
If laser welding is used to join steel components, then structural integrity is enhanced, but visible welding traces affect aesthetic appearance
Solution Approach 1:
The patent extracts the welding operation to the inner surfaces of components that are not visible from the exterior. By positioning weld joints on the rear side of the door assembly and using the frame structure to conceal connection points, the design removes visible welding traces from the aesthetic surfaces while maintaining strong structural bonds through laser welding of the steel frame, support portion, and coupling member
3Reliability
If zinc galvanized steel is used for frame and coupling members, then corrosion resistance and strength are improved, but manufacturing complexity increases
Solution Approach 1:
The patent applies zinc galvanization to the steel frame, support portion, and coupling member during the initial press manufacturing stage rather than as a separate post-processing step. This preliminary application of the protective coating integrates corrosion protection into the base manufacturing process, avoiding additional manufacturing complexity while ensuring uniform zinc coverage and maintaining the reliability benefits of corrosion-resistant steel 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
The solution maintains fixation strength, eliminates visible welding traces, enhances aesthetic appeal, simplifies the manufacturing and assembly processes, and improves product quality and reliability.
Implementation Method 1
utilizing laser welding and press processes to enhance structural integrity
Implementation Method 2
injecting liquid-foam for insulation and assembly
Data Source
AI summary
There is disclosed a refrigerator door including a front panel for defining a front exterior appearance thereof, a door liner for defining a rear exterior appearance thereof, a frame for defining both lateral exterior appearance thereof, the frame formed of steel, a support portion provided in an inner portion of the frame to support the front panel, the support portion formed of steel, an upper cap decorative portion for sealing upper portions of the front panel and the door liner, a lower cap decorative portion for sealing lower portions of the front panel and the door liner, and a coupling member provided in an inner portion of the frame to couple the upper cap decorative portion and the lower cap decorative portion to each other, the coupling member formed of steel, wherein the support portion is welded to the frame and the coupling member is welded to the frame.