refrigerator
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Solution Overview
Problem
The existing manufacturing process for refrigerator inner cases, which are typically formed using vacuum forming, results in large, cumbersome components that are difficult to transport and store, and expose unsightly coupling lines due to heat shrinkage, affecting the appearance quality.
Innovation Solution
The inner case is assembled from multiple plates formed by injection molding, with a coupling structure that includes upward extensions and grooves to conceal the coupling lines, and features a lamp accommodating space with a cover to enhance aesthetics and functionality.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If the inner case is manufactured as one piece using vacuum forming, then the structural integrity is maintained, but the transportation and storage become difficult due to large size
Solution Approach 1:
The inner case is divided into multiple plates (front plate, rear plate, left plate, right plate, upper plate, lower plate) that can be separately manufactured and assembled. This segmentation allows each plate to be compact and easy to transport, while the assembled structure maintains the required structural integrity through coupling structures between the plates.
2Ease of manufacture
If the inner case is manufactured as one piece using vacuum forming, then the manufacturing process is simplified, but the coupling lines become exposed due to heat shrinkage affecting appearance quality
Solution Approach 1:
By dividing the inner case into multiple separately molded plates, each plate can be manufactured without the heat shrinkage issues affecting the entire large structure. The coupling lines between plates are positioned to minimize visual impact, and the segmentation allows for better control of dimensional stability in each component.
Solution Approach 2:
The coupling lines between plates are strategically positioned in three-dimensional space, utilizing the depth and angles of the inner case structure to hide or minimize the visibility of joint lines from the front viewing angle, thus improving appearance quality.
3Ease of operation
If multiple plates are assembled to form the inner case, then transportation and storage become easier, but the device complexity increases due to assembly requirements
Solution Approach 1:
Multiple plates are merged into a single integrated inner case structure through coupling structures that join the plates together. This merging maintains the benefits of segmented manufacturing for transportation while creating a unified structure that functions as a single unit during assembly and installation.
Solution Approach 2:
The coupling structures between plates are designed to enable self-alignment and self-assembly, reducing the complexity of the assembly process. The plates can be coupled together through their own structural features without requiring additional fastening components or complex assembly procedures.
Data Source
AI summary
A refrigerator including: an inner case forming a storage compartment with an open front side and comprising a plurality of plates formed by injection molding; an outer case coupled to an outside of the inner case; and an insulation material between the inner case and the outer case. The plurality of plates includes an upper plate and a plurality of lateral plates coupled to the upper plate. The upper plate includes an upper plate body and an upper plate coupler. The each of the plurality of lateral plates includes a lateral plate body and a lateral plate coupler. The upper plate coupler includes an upward extension portion extending upward from the upper plate body and spaced from the lateral plate body. The inner case includes a groove recessed upward extending in a front and rear direction between the upward extension portion and the lateral plate body.