U.S. patent application number 11/657055 was filed with the patent office on 2007-10-04 for refrigerator and method of manufacturing inner case thereof.
This patent application is currently assigned to SAMSUNG GWANGJU ELECTRONICS CO., LTD.. Invention is credited to Byoung Won Jung, Jung Joo Moon, Sang Sul Park, Keum Bae Yoo, Kwon Jae Yoo.
Application Number | 20070227179 11/657055 |
Document ID | / |
Family ID | 38236447 |
Filed Date | 2007-10-04 |
United States Patent
Application |
20070227179 |
Kind Code |
A1 |
Yoo; Keum Bae ; et
al. |
October 4, 2007 |
Refrigerator and method of manufacturing inner case thereof
Abstract
A refrigerator having an inner case with increased strength and
a method of manufacturing the same. The refrigerator includes a
cooling system, a body coupled to the cooling system, a door
coupled to the body, and a plurality of reinforcing protrusions.
The body includes an outer case encasing an inner body case having
a storage compartment defined therein. The door includes an outer
door case encasing an inner door case. The door is coupled to the
body to provide access to the storage compartment which is cooled
by the cooling system. The plurality of reinforcing protrusions is
disposed on at least one inner surface of either the inner body
case or the inner door case. The plurality of reinforcing
protrusions allows for manufacturing thinner inner cases for
refrigerators that cannot be easily deformed and have a low product
defect rate.
Inventors: |
Yoo; Keum Bae; (Gwangsan-gu,
KR) ; Park; Sang Sul; (Gwangsan-gu, KR) ;
Moon; Jung Joo; (Gwangsan-gu, KR) ; Jung; Byoung
Won; (Gwangsan-gu, KR) ; Yoo; Kwon Jae;
(Gwangsan-gu, KR) |
Correspondence
Address: |
BLANK ROME LLP
600 NEW HAMPSHIRE AVENUE, N.W.
WASHINGTON
DC
20037
US
|
Assignee: |
SAMSUNG GWANGJU ELECTRONICS CO.,
LTD.
|
Family ID: |
38236447 |
Appl. No.: |
11/657055 |
Filed: |
January 24, 2007 |
Current U.S.
Class: |
62/440 ; 312/401;
62/298 |
Current CPC
Class: |
F25D 23/066 20130101;
F25D 2500/02 20130101 |
Class at
Publication: |
62/440 ; 62/298;
312/401 |
International
Class: |
F25D 19/00 20060101
F25D019/00; A47B 96/04 20060101 A47B096/04; F25D 11/00 20060101
F25D011/00 |
Foreign Application Data
Date |
Code |
Application Number |
Mar 31, 2006 |
KR |
10-2006-0029932 |
Claims
1. A refrigerator comprising of: a cooling system; a body coupled
to the cooling system, the body having an outer body case encasing
an inner body case, the inner body case having a storage
compartment defined therein cooled by the cooling system; a door
coupled to the body providing access to the storage compartment,
the door having an outer door case encasing an inner door case; and
a plurality of reinforcing protrusions disposed on at least one
inner surface of either the inner body case or the inner door
case.
2. A refrigerator according to claim 1, wherein each of the
plurality of reinforcing protrusions is shaped as quadrangular
pyramid with a substantially rectangular base.
3. A refrigerator according to claim 1, wherein each of the
plurality of reinforcing protrusions are disposed adjacent to each
other to form a substantially rectangular portion disposed on an
inner surface of either the inner body case or the inner door
case.
4. A refrigerator according to claim 3, wherein the plurality of
reinforcing protrusions is disposed on a top surface, a bottom
surface, a left side surface, a right side surface, and a rear
surface of either the inner body case or the inner door case.
5. A refrigerator according to claim 1, wherein each of the
plurality of reinforcing protrusions is formed in the shape of a
regular quadrangular pyramid having a substantially rectangular
base and a height less than a length of the base.
6. A refrigerator according to claim 5, wherein each of the
plurality of reinforcing protrusions has a height approximately
1/10 of the length of the base.
7. A refrigerator according to claim 1, wherein the plurality of
reinforcing protrusions are disposed on both inner body case and
inner door case.
8. An inner case for a refrigerator comprising of: a plurality of
sidewalls; a rear wall disposed adjacent to an edge of one of the
sidewalls thereby defining a storage compartment, the storage
compartment being enclosed with a door providing access to the
storage compartment; and a means for reinforcing the storage
compartment provided on at least one inner surface of the storage
compartment.
9. An inner case for a refrigerator according to claim 8, wherein
the means for reinforcing includes a plurality of reinforcing
protrusions each shaped as a quadrangular pyramid with a
substantially rectangular base.
10. An inner case for a refrigerator according to claim 9, wherein
each of the plurality of reinforcing protrusions are disposed
adjacent to each other to form a substantially rectangular portion
disposed on an inner surface of the inner case.
11. An inner case for a refrigerator according to claim 10, wherein
the plurality of reinforcing protrusions are disposed on a top
surface, a bottom surface, a left side surface, a right side
surface, and a rear surface of the storage compartment.
12. An inner case for a refrigerator according to claim 9, wherein
each of the plurality of reinforcing protrusions is formed in the
shape of a regular quadrangular pyramid having a substantially
rectangular base and a height less than a length of the base.
13. An inner case for a refrigerator according to claim 12, wherein
each of the plurality of reinforcing protrusions has a height
approximately 1/10 of a length of the base.
14. A method of manufacturing an inner case for refrigerators,
comprising: (a) heating a resin sheet; (b) placing the heated resin
sheet under an opening of a vacuum case; (c) evacuating an interior
of the vacuum case to suction a portion of the resin sheet into the
opening of the vacuum case so as to deform the resin sheet; (d)
placing a mold having a shape corresponding to the inner case under
the deformed resin sheet; (e) molding the deformed resin sheet by
bringing together the vacuum case and the mold so that the deformed
resin sheet contacts the mold to form an inner case preform having
a storage compartment and a reinforcement including a plurality of
reinforcing protrusions; (f) cooling the inner case preform; and
(g) separating the inner case preform from the mold.
15. A method according to claim 14, further comprising the step of
forming each of the reinforcing protrusions in the shape of a
quadrangular pyramid with a substantially rectangular base.
16. A method according to claim 14, further comprising the step of
forming each of the reinforcing protrusions adjacent to one another
to form a substantially rectangular structure.
17. A method according to claim 14, further comprising the step of
forming each of the reinforcing protrusions as a regular
quadrangular pyramid with a substantially rectangular base and a
height less than a length of the base.
18. A method according to claim 17, further comprising the step of
forming each of the reinforcing protrusions shaped as a
quadrangular pyramid having a height approximately 1/10 of a length
of the base.
Description
CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This application claims benefit of priority under 35 U.S.C.
.sctn.119(a) from Korean Patent Application No. 2006-29932, filed
on Mar. 31, 2006, in the Korean Intellectual Property Office, the
disclosure of which is incorporated by reference herein in its
entirety. [Add related patents and patent applications]
FIELD OF THE INVENTION
[0002] The present invention relates generally to the field of
refrigerators and methods of manufacturing an inner case thereof.
In particular, the present invention relates to a refrigerator
having an inner case that is reinforced and a method of
manufacturing the same.
BACKGROUND OF THE INVENTION
[0003] Generally, a refrigerator includes a body having storage
compartments, such as a refrigerating compartment to store food in
a refrigerated state, and a freezing compartment to store food in a
frozen state, doors coupled to the body to access the storage
compartments, and a cooling system to cool the storage
compartment.
[0004] The body includes an inner body case having at least one
space necessary to form the storage compartment and an outer body
case to surround the inner body case. The outer body case is
preferably made of metal. When the inner body case is coupled with
the outer body case, an insulation space is formed between the
inner body case and the outer body case. The insulation space may
be filled with an insulation material. The door typically includes
an inner door case and an outer door case. An insulation material
may fill the space between the inner door case and the outer door
case. The cooling system usually includes a compressor and a heat
exchanger. The cooling system is mounted in a machine room disposed
at one side of the lower part of the body.
[0005] For a conventional refrigerator, during the primary and
secondary molding of the inner body and door cases, the thickness
of the inner body case and inner door case are often reduced at
specific regions. As a result, the strength of the inner cases is
reduced, leading to a higher product defect rate. Furthermore, when
filling the space between the inner and outer cases, the thin parts
of the inner cases may protrude away from the outer case due to the
pressure of the filling, which leads to the deformation of the
inner cases. Then, the entire body must be discarded. Also,
attaching resin sheets to the thin parts of the inner cases or
using thicker resin sheets for molding to increase the strength of
the inner cases increases the production time and manufacturing
costs.
SUMMARY OF THE INVENTION
[0006] Therefore, it is an aspect of the invention to provide a
refrigerator including an inner case which is thin and not easily
deformed by way of an improvement to the structure of the inner
case, and a method of manufacturing such an inner case.
[0007] In accordance with one aspect, the present invention
provides a refrigerator comprising of: a cooling system; a body
coupled to the cooling system, the body having an outer body case
encasing an inner body case, the inner body case having a storage
compartment defined therein cooled by the cooling system; a door
coupled to the body providing access to the storage compartment,
the door having an outer door case encasing an inner door case; and
a plurality of reinforcing protrusions disposed on at least one
surface of either the inner body case or the inner door case.
[0008] Preferably, each of the plurality of reinforcing protrusions
is shaped as quadrangular pyramid with a substantially rectangular
base.
[0009] Preferably, each reinforcing protrusion is disposed adjacent
to each other to form a rectangular portion disposed on an inner
surface of either the inner body case or inner door case.
[0010] Preferably, the plurality of reinforcing protrusions is
disposed on a top surface, a bottom surface, a left side surface, a
right side surface, and a rear surface of either the inner body
case or the inner door case.
[0011] Preferably, each reinforcing protrusion is formed in the
shape of a regular quadrangular pyramid, and each reinforcing
protrusion has a height less than a length of the base of each
reinforcing protrusion.
[0012] Preferably, the height of each reinforcing protrusion is
approximately 1/10 of the length of the base of each reinforcing
protrusion.
[0013] Preferably, the plurality of reinforcing protrusions are
disposed on both inner body case and inner door case.
[0014] In accordance with another aspect, the present invention
provides an inner case for a refrigerator comprising of: a
plurality of sidewalls; a rear wall disposed adjacent to an edge of
one of the sidewalls thereby defining a storage compartment, the
storage compartment being enclosed with a door providing access to
the storage compartment; and a means for reinforcing provided on at
least one inner surface of the storage compartment.
[0015] Preferably, the means for reinforcing includes a plurality
of reinforcing protrusions each shaped as a quadrangular pyramid
with a substantially rectangular base.
[0016] Preferably, each of the plurality of reinforcing protrusions
are disposed adjacent to each other to form a substantially
rectangular portion disposed on an inner surface of the inner case.
The plurality of reinforcing protrusions may be disposed on a top
surface, a bottom surface, a left side surface, a right side
surface, and a rear surface of the storage compartment.
[0017] Preferably, each of the plurality of reinforcing protrusions
is formed in the shape of a regular quadrangular pyramid having a
substantially rectangular base and a height less than a length of
the base.
[0018] Preferably, each of the plurality of reinforcing protrusions
has a height approximately 1/10 of a length of the base.
[0019] In accordance with another aspect, the present invention
provides a method of manufacturing an inner case for refrigerators,
comprising of: (a) heating a resin sheet; (b) placing the heated
resin sheet under an opening of a vacuum case; (c) evacuating an
interior of the vacuum case to suction a portion of the resin sheet
into the opening of the vacuum case so as to deform the resin
sheet; (d) placing a mold having a shape corresponding to the inner
case under the deformed resin sheet; (e) molding the deformed resin
sheet by bringing together the vacuum case and the mold so that the
deformed resin sheet contacts the mold to form an inner case
preform having a storage compartment and a reinforcement including
a plurality of reinforcing protrusions; (f) cooling the inner case
preform; and (g) separating the inner case preform from the
mold.
[0020] Preferably, forming each of the reinforcing protrusions in
the shape of a quadrangular pyramid with a substantially
rectangular base.
[0021] Preferably, forming the reinforcing protrusions adjacent to
one another to form a substantially rectangular structure.
[0022] Preferably, forming each of the reinforcing protrusions as a
regular quadrangular pyramid with a height less than a length of
the base of each reinforcing protrusion.
[0023] Preferably, forming each of the reinforcing protrusions
shaped as a quadrangular pyramid having a height approximately 1/10
of a length of the base.
[0024] Additional aspects and/or advantages of the invention will
be set forth in part in the description which follows and, in part,
will be obvious from the description, or may be learned by practice
of the invention.
BRIEF DESCRIPTION OF THE DRAWINGS
[0025] A more complete appreciation of the invention and many of
the aspects and advantages thereof will be readily obtained as the
same becomes better understood by references to the following
detailed description when considered in conjunction with the
accompanying drawings, wherein:
[0026] FIG. 1 is an exploded, perspective view illustrating an
inner body case for a refrigerator according to an embodiment of
the present invention;
[0027] FIG. 2 is an exploded, perspective view illustrating an
inner door case of a refrigerator according to an embodiment of the
present invention;
[0028] FIGS. 3A to 3D are views illustrating a method of
manufacturing an inner body case for a refrigerator according to an
embodiment of the present invention;
[0029] FIG. 4 is a perspective view schematically illustrating a
mold for molding the inner body case for a refrigerator according
to the embodiment of the present invention; and
[0030] FIGS. 5 and 6 are graphs illustrating improved effects of
the inner case for a refrigerator according to the embodiment of
the present invention.
DETAILED DESCRIPTION OF THE INVENTION
[0031] Reference will now be made in detail to the embodiment of
the present invention, examples of which are illustrated in the
accompanying drawings, wherein like reference numerals refer to
like elements throughout. The embodiment is described below to
explain the present invention by referring to the figures.
[0032] FIG. 1 is an exploded perspective view illustrating a
refrigerator according to an embodiment of the present invention.
The refrigerator may include a body 10, two doors 40 and 50 coupled
to the body 10, and a cooling system 60 mounted in the body 10.
[0033] The body 10 may include an inner body case 20 and an outer
body case 30 surrounding the inner body case 20. The inner body
case 20 is preferably made of resin having high impact resistance
and high heat resistance, such as an ABS resin. The outer body case
30 is preferably made of metal.
[0034] The inner body case 20 is partitioned into a freezing
compartment 21 and a refrigerating compartment by a partition 23.
Guide rails 24, to which shelves (not shown) may be coupled, are
disposed on left side surfaces 21b and 22b and right side surfaces
(not shown) of the freezing compartment 21 and the refrigerating
compartment 22. Reinforcements 25 are disposed on an inner surface
of the inner body case 20. The reinforcements 25 may be disposed on
top surfaces (not shown), bottom surfaces 21a and 22a, the left
side surfaces 21b and 22b, the right side surfaces (not shown), and
rear surfaces (not shown).
[0035] The reinforcements 25 increase the strength of the inner
body case 20 to prevent deformation of the inner body case 20. The
reinforcements 25 are preferably a rectangular portion composed of
a plurality of reinforcing protrusions 26 disposed adjacent to one
another. Each reinforcing protrusion 26 is preferably formed in the
shape of a quadrangular pyramid having four triangular faces 27
which are inclined upward to converge on the vertex of the pyramid.
Preferably, each reinforcing protrusion 26 has the same base widths
W1 and W2. The reinforcing protrusion 26 has a height H less than
the widths W1 and W2. More preferably, the height H of each
reinforcing protrusion 26 is 1/10 of the widths W1 and W2. In one
embodiment, the widths W1 and W2 of each reinforcing protrusion 26
is 10 mm.
[0036] However, the reinforcing protrusions 26 constituting the
reinforcements 25 is not restricted to the illustrated and
described structure. For example, the base widths W1 and W2 of the
reinforcing protrusion 26 may be different from each other. The
height H of the reinforcing protrusion 26 may be greater or less
than 1/10 of the base width W1 and W2.
[0037] FIG. 2 is an exploded perspective view schematically
illustrating the door 40 of the refrigerator according to the
present invention.
[0038] As shown in FIG. 2, the door 40 includes an inner door case
41 and an outer door case 42. The inner door case is preferably 41
is preferably made of resin. The outer door case 42 is preferably
made of metal, as in the body 10.
[0039] As seen in FIG. 2, reinforcements 43 are disposed on an
inner surfaces of the inner door case 40. Reinforcements 43 may be
disposed on a top surface (not shown), a bottom surface 41a, a left
side surface 41b, a right side surface (not shown), and a rear
surface 41c. A plurality of reinforcing protrusions 44 constitutes
each reinforcement 43. Each reinforcing protrusion 44 may be formed
in the shape of the same quadrangular pyramid as the reinforcing
protrusions 26 of the inner body case 20.
[0040] The reinforcing protrusions 44 constituting the
reinforcements 43 are not restricted to the illustrated and
described structure. For example, the base width W1 and W2 of the
reinforcing protrusions 44 may be different from each other. The
height H of the reinforcing protrusions 44 may be greater or less
than 1/10 of the base width W1 and W2.
[0041] Hereinafter, a method of manufacturing the inner body case
20 of the refrigerator according to the present invention will be
described with reference to FIGS. 3A to 4.
[0042] The method of manufacturing the inner body case 20 comprises
seven operations. First operation is heating. As shown in FIG. 3A,
a resin sheet 70 is heated by a heater 110, while the resin sheet
70 is held by a jig 120, such that the resin sheet 70 can be easily
deformed.
[0043] Second, as shown in FIG. 3B, the heated resin sheet 70 is
placed under a vacuum case 130 having a molding space 131.
[0044] Third, the interior of the vacuum case 130 is evacuated such
that a portion of the heated resin sheet 70 is suctioned into the
vacuum space 131. As a result, the resin sheet 70 deforms into two
volumes which will correspond to the freezing compartment 21 and
the refrigerating compartment 22. In this way, the resin sheet 70
is primarily molded.
[0045] Fourth, a mold 140 having a shape corresponding to the inner
body case 20 is placed under the deformed resin sheet 70.
[0046] Fifth, as shown in FIG. 3C, the vacuum case 130 and the mold
140 are brought together such that the open bottom of the vacuum
case 130 is covered by the mold 140. Then high-pressure air is
blown into the vacuum case 130. As a result, the resin sheet 70 is
brought into tight contact with the mold 140.
[0047] As shown in FIG. 3D, an inner case preform 75 is produced.
The inner case preform 75 has the freezing compartment 21, the
refrigerating compartment 22, and the reinforcements 25. Next, the
inner case preform 75 is cooled.
[0048] Finally, the inner case preform 75 is separated from the
mold 140. Although not shown in the drawing, unnecessary portions
are removed from the inner case preform 75, and grooves necessary
for assembly are formed in the inner case preform 75.
[0049] As shown in FIG. 4, the mold 140 used in the molding
operation of the inner body case manufacturing method includes two
molding parts: a freezing compartment molding part 141 and a
refrigerating compartment molding part 142. The freezing
compartment molding part 141 and the refrigerating compartment
molding part 142 have elongate grooves 143 to form the guide rails
24 and concave-convex parts 144 to form the reinforcements 25.
[0050] Each concave-convex part 144 may include a plurality of
protrusion forming grooves 145, which correspond to the reinforcing
protrusions 26 (see FIG. 1), disposed adjacent to each other to
form a substantially rectangular portion. Preferably, each
protrusion forming groove 145 has horizontal and vertical widths of
10 mm and a depth of 1 mm, which is 1/10 of the horizontal and
vertical widths. Consequently, when the heated resin sheet 70 is
brought into tight contact with the mold 140 in the molding
operation, reinforcements 25 are formed on the resin sheet 70.
Also, each reinforcement 25 includes the plurality of reinforcing
protrusions 26 having base widths W1 and W2 of 10 mm and height H
of 1 mm.
[0051] The inner door case 41 is manufactured by the same method as
the inner body case 20 manufacturing method. Although, in this
case, a mold constructed in a shape corresponding to the shape of
the door and having concave-convex parts is used in the molding
operation.
TABLE-US-00001 TABLE 1 Common resin Resin sheet with sheet
reinforcements Difference MD TD MD TD MD TD Remark Bending 8.83
6.86 12.53 12.42 3.7.uparw. 5.56.uparw. 41 81% strength (41.9%)
(81.04%) improved (kg/mm.sup.2) Bending 269.41 244.72 475.45 471.65
206.04.uparw. 226.93.uparw. 76 92% coefficient (76.04%) (92.73%)
improved (kg/mm.sup.2) (MD: Main Direction, TD: Tangential
Direction)
[0052] Table 1 compares the strength of a common resin sheet
without reinforcements 25 or 43 and a resin sheet with
reinforcements 25 or 43. When reinforcements 25 or 43, each
including the plurality of reinforcing protrusions 26 or 44, are
formed on the common resin sheet, the bending strength of the
common resin sheet is improved by at least 41%.
[0053] Consequently, the strength of the inner body case 20 and
inner door case 41 of the refrigerator according to the present
invention is greater than that of the inner cases of conventional
refrigerators. Therefore, the inner body case 20 or inner door case
41 of the refrigerator according to the present invention is not
easily deformed.
[0054] Furthermore, when the reinforcements 25 and 43, each
including the plurality of reinforcing protrusions 26 and 44, are
formed at the inner body case 20 and inner door case 41, it is
possible to reduce the thickness of the inner cases 20 and 41 and
to reduce the product defect rate. Specifically, as shown in FIGS.
5 and 6, as the thickness of the inner body case 20 and inner door
case 41 is reduced from 4 mm to 3.6 mm, i.e., approximately by 10%,
the product defect rate is reduced from 5% to 2%. Consequently,
manufacturing costs are reduced, and product quality is
improved.
[0055] As apparent from the above description, reinforcements each
including a plurality of reinforcing protrusions are formed at
inner surfaces of inner body and door cases. Consequently, it is
possible to manufacture thinner inner cases for refrigerators which
are not easily deformed and have a low defective product rate.
Therefore, it is possible to reduce the manufacturing costs of the
refrigerators and improve the reliability of products.
[0056] Although a few embodiments of the present invention have
been shown and described, it would be appreciated by those skilled
in the art that changes may be made in this embodiment without
departing from the principles and spirit of the invention, the
scope of which is defined in the claims and their equivalents.
* * * * *