Refrigerator Foaming Layer Segmentation for Uniform Insulation Density
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Solution Overview
Problem
In super-thin and large-volume refrigerators, the narrow space between the inner liner and the housing poses challenges for uniform foaming material distribution, leading to high costs and inefficiencies in the foaming process, as excessive material is often required to achieve uniform density, especially in the middle beam area.
Innovation Solution
A sealing device is strategically placed between the first and third foaming zones to control the flow of foaming material, preventing excessive accumulation in the middle beam, while a conduit is used to guide the material between the inner liners and the housing, ensuring uniform density across the foaming zones.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If a plurality of guns are used to fill foaming material at the back plate, then the foaming material distribution is improved, but the manufacturing cost increases and production efficiency decreases
Solution Approach 1:
The foaming process is segmented into multiple zones (first foaming zone, second foaming zone, third foaming zone) with different filling strategies. The sealing device segments the flow path to control material distribution to different areas at different times, enabling uniform distribution while using a single gun.
Solution Approach 2:
The sealing device is pre-positioned to control the flow path before foaming material enters. This preliminary action guides the material flow to achieve uniform distribution without requiring multiple guns, thereby maintaining high production efficiency.
2Productivity
If one gun is used to fill material at the bottom steel, then the production efficiency is improved, but the foaming material accumulates excessively in the middle beam area
Solution Approach 1:
The sealing device dynamically controls the flow path of foaming material by being positioned to allow material to pass through the first foaming zone and second foaming zone before reaching the middle beam area. This dynamic control prevents excessive accumulation while maintaining production efficiency with a single gun.
Solution Approach 2:
Different regions of the refrigerator are given different filling characteristics. The first foaming zone receives material first, then the second foaming zone, and finally the third foaming zone in the middle beam area. This local quality approach ensures uniform density across different regions while using one gun.
3Manufacturing precision
If excessive foaming material is filled to achieve uniform density, then the foaming layer density uniformity is improved, but the material consumption and cost increase
Solution Approach 1:
The sealing device acts as a feedback control mechanism that regulates foaming material flow to different zones. By controlling the flow path and timing, it ensures that material is distributed uniformly without over-filling, thereby reducing material consumption while achieving uniform density.
Solution Approach 2:
The sealing device is pre-positioned to control material flow distribution before filling occurs. This preliminary configuration ensures that foaming material reaches different zones in the correct sequence and quantity, achieving uniform density without excessive material consumption.
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 limits excessive foaming material entry into the middle beam, maintaining uniform foaming density and reducing costs by optimizing the foaming material distribution, thereby enhancing the manufacturing efficiency and thermal insulation effectiveness.
Implementation Method 1
a foaming layer formed between the housing, the freezing inner liner and the refrigerating inner liner
Implementation Method 2
a sealing device (5) is disposed in a foaming process, the sealing device (5) at least partially spaces the first foaming zone (41) apart from the third foaming zone (43)
Data Source
Figure 1
AI summary
A refrigerator(100) which comprises a housing, a refrigerating inner liner(1) and a freezing inner liner(2) arranged in the housing, and a foaming layer formed between the housing, the refrigerating inner liner(1) and the freezing inner liner(2); the housing comprises a back plate(31) and two side plates extending forward from the back plate(31), and the foaming layer comprises a first foaming zone(41) disposed close to the back plate(31), a second foaming zone disposed close to the side plates and a third foaming zone(43) disposed in an interior of the middle beam, and the third foaming zone(43) is connected to the second foaming zone; the refrigerator(100) further comprises a sealing device(5) that at least partially spaces the first foaming zone(41) apart from the third foaming zone(43). Further disclosed is a manufacturing method of a refrigerator. After the foaming material reaches the first foaming zone(41), a lot of foaming material may be limited from directly entering the interior of the middle beam due to the blocking of the sealing device(5), so that the density of the foaming material in the interior of the middle beam will not be too large, and the filling uniformity of the foaming material can be further improved effectively.