refrigerator

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Solution Overview

Problem

The vacuum forming method for forming the inner case of refrigerators limits the accuracy in shaping and coupling to surrounding components, leading to gaps or steps between the inner and outer cases.

Innovation Solution

The inner case is formed by assembling a plurality of plates through injection molding, with locking ribs on the front flange to enhance coupling to the outer case, preventing gaps or steps, and incorporating support ribs for the hot pipe to maintain thermal insulation and structural integrity.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Ease of manufacture

If vacuum forming method is used to form the inner case, then the manufacturing process is simple, but the shaping accuracy and coupling precision deteriorate

Engineering Contradiction:

Improvemanufacturing process simplicityVSAvoidshaping accuracy and coupling precision

Core Design Contradiction:

Ease of manufactureVSManufacturing precision

Solution Approach 1:

The inner case is divided into multiple plates that are separately injection-molded with high precision, then assembled together. This segmentation allows each plate to be manufactured with high accuracy while maintaining ease of production through standardized injection molding processes.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The manufacturing method changes from vacuum forming to injection molding, fundamentally altering the production parameter to achieve both high precision and ease of manufacture. Injection molding provides superior dimensional accuracy and surface finish compared to vacuum forming.

Inventive Principle:

Principle #35Parameter changes

2Ease of manufacture

If vacuum forming method is used to form the inner case, then the manufacturing process is simple, but the coupling structure with surrounding components deteriorates

Engineering Contradiction:

Improvemanufacturing process simplicityVSAvoidcoupling structure complexity

Core Design Contradiction:

Ease of manufactureVSDevice complexity

Solution Approach 1:

Coupling structures such as locking ribs and insertion grooves are pre-formed during the injection molding process itself, rather than being added as separate operations. This preliminary action integrates the coupling structure creation into the main manufacturing process, avoiding additional complexity.

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

The coupling structures are integrated directly into the plate components through injection molding, merging the formation of the plate body and its coupling features into a single manufacturing operation, thereby simplifying the overall structure.

Inventive Principle:

Principle #5Merging (Combining)

3Manufacturing precision

If injection molding is used to form multiple plates for the inner case, then the shaping accuracy and coupling precision are improved, but the device complexity increases

Engineering Contradiction:

Improveshaping accuracy and coupling precisionVSAvoidnumber of plates and assembly structure

Core Design Contradiction:

Manufacturing precisionVSDevice complexity

Solution Approach 1:

The inner case is segmented into multiple plates that can be manufactured independently with high precision injection molding, then assembled using integrated coupling structures. This segmentation enables parallel production and maintains precision while managing complexity through modular design.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The injection molding process serves multiple functions: forming the plate body, creating coupling structures, and enabling precise dimensional control. This multi-functionality of the manufacturing process justifies the increased device complexity by delivering superior precision.

Inventive Principle:

Principle #6Universality (Multi-functionality)

4Strength

If locking ribs are added to the front flange to prevent movement, then the coupling strength is improved, but the manufacturing complexity increases

Engineering Contradiction:

Improvecoupling strengthVSAvoidstructure complexity

Core Design Contradiction:

StrengthVSDevice complexity

Solution Approach 1:

The locking ribs are pre-formed as integral features of the front flange during injection molding, rather than being added as separate components or operations. This preliminary formation of coupling features maintains strength while avoiding additional manufacturing complexity.

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

The locking ribs are merged with the front flange as a single injection-molded component, combining the structural element and the coupling mechanism into one integrated part, thereby achieving strong coupling without increasing overall device complexity.

Inventive Principle:

Principle #5Merging (Combining)

Data Source

PatentEP4421428B1refrigerator

Publication Date: 2026.03.04 SAMSUNG ELECTRONICS CO LTD

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AI summary

A refrigerator includes a main body including an inner case including plates each formed by injection molding, an outer case coupled to the inner case. At least one of plates include a front flange forming a front surface of the at least one plate and coupled to the outer case, the outer case includes an insertion groove into which the front flange is inserted. The front flange includes locking ribs arranged to prevent the front flange from moving in a direction opposite to an insertion direction of the front flange based on inserting the front flange into the insertion groove, the locking ribs are injection molded integrally with the at least one plate and protrude from the front flange so as to be locked on the outer case. The locking ribs are spaced apart from each other along a longitudinal direction of the front flange.