U.S. patent number 3,834,177 [Application Number 05/311,722] was granted by the patent office on 1974-09-10 for refrigerator cabinet structure and its manufacture.
This patent grant is currently assigned to Philco-Ford Corporation. Invention is credited to John A. Scarlett.
United States Patent |
3,834,177 |
Scarlett |
September 10, 1974 |
REFRIGERATOR CABINET STRUCTURE AND ITS MANUFACTURE
Abstract
In the manufacture of refrigerator cabinets of the dual
compartment type, using vacuum forming techniques to mold an
integrally formed double cavity liner, desired communicating fluid
passages are formed between compartments, through confronting liner
walls of adjacent compartment sections. While the liners are still
in a pliable state, small sections of confronting liner walls at
locations where passages are desired, are moved, with relation to
one another, toward and into abutting engagement. The liners are
then allowed to cool, followed by piercing the engaged liner wall
sections to form the desired communicating passages.
Inventors: |
Scarlett; John A. (Richmond,
IN) |
Assignee: |
Philco-Ford Corporation (Blue
Bell, PA)
|
Family
ID: |
23208166 |
Appl.
No.: |
05/311,722 |
Filed: |
December 7, 1972 |
Current U.S.
Class: |
62/288; 62/419;
62/447; 62/444; 62/465 |
Current CPC
Class: |
B29C
51/34 (20130101); F25D 17/065 (20130101); B29C
51/32 (20130101); F25D 23/064 (20130101); F25D
17/045 (20130101); F25D 2400/04 (20130101); F25D
2400/06 (20130101); F25D 2317/067 (20130101); F25D
2317/0653 (20130101) |
Current International
Class: |
B29C
51/32 (20060101); B29C 51/34 (20060101); B29C
51/30 (20060101); F25D 23/06 (20060101); F25D
17/06 (20060101); F25D 17/04 (20060101); F25d
021/14 () |
Field of
Search: |
;62/419,447,276,465,288,444 |
References Cited
[Referenced By]
U.S. Patent Documents
Primary Examiner: Wye; William J.
Attorney, Agent or Firm: Hargis, III; Harry W. Sanborn;
Robert D.
Claims
I claim:
1. A refrigerator including: a unitary liner having wall sections
defining first and second compartments, a wall section defining
said first compartment being disposed in confronting spaced
relation to a wall section defining said second compartment;
cooling coil means in said first compartment; drain trough means
disposed below said cooling coil means, said drain trough means
being integrally molded with a first compartment-defining wall
section of said unitary liner; passage means extending between said
compartments, said passage means being defined by integrally formed
tubular portions of at least one of said confronting spaced wall
sections, said tubular portions extending between and having open
ends each communicating with a corresponding one of said
compartments; fan means for circulating air through said passage
means and over said cooling coil means to cool said second
compartment; and inwardly spaced molded portions of the liner wall
sections defining said first compartment, said portions
accommodating provision of relatively thickened insulated regions
adjacent said cooling coil means.
2. A refrigerator including: a unitary liner molded from
thermoplastic material and having walls defining first and second
compartments, one wall of one compartment being disposed in
confronting spaced relationship to a wall of the other compartment;
cooling coil means in said first compartment; inwardly spaced
molded wall sections of said first liner, which sections
accommodate provision of relatively thickened insulated regions
adjacent said cooling coil means; passage means extending between
said compartments, said passage means being defined by integrally
formed tubular portions of at least one of said confronting spaced
walls, said tubular portions extending between and having open ends
each communicating with the interior of a corresponding one of said
compartments; and fan means for circulating air through said
passage means and over said cooling coil means to cool said second
compartment.
Description
CROSS REFERENCE TO RELATED DISCLOSURE
This invention, in certain aspects thereof, is briefly described in
the copending disclosure of Norman F. Houghton, Ser. No. 235,968,
now U.S. Pat. No. 3,781,394, filed Mar. 20, 1972, entitled "Method
and Apparatus for Forming Articles from Plastic Sheet Material,"
and assigned to the assignee of the present invention.
Additionally, certain of the mold manipulating techniques hereof
are within the purview of the claims of the aforesaid pending
disclosure, and of Houghton, Ser. No. 73,761, now U.S. Pat. No.
3,709,968, filed Sept. 21, 1970, and also assigned to the assignee
of the present invention.
BACKGROUND OF THE INVENTION
This invention relates to refrigerator cabinet construction, and
particularly to the formation of communicating passages between
adjacent storage compartments defined by molded thermoplastic liner
sections.
In a dual compartment refrigerator, of one well known type, a
refrigeration coil is positioned in one of two insulated
compartments having steel liners, communicating air passages are
formed between the compartments, and a fan is positioned to
circulate air between the compartments to cool the same to
predetermined desired temperatures. However, if the liners of such
a refrigerator are of the molded plastic type, and the insulation
is molded therebetween and between the liner and the outer shell,
difficulties are encountered in arriving at a suitable and
economical means for forming the air passages.
I therefore propose as a primary objective of my invention a novel
method for forming communicating passages of the aforesaid type,
which method is carried out in the liner molding operation.
It is a further objective of my invention to form communicating
fluid passages between adjacent liners by utilizing the liner
material itself to define such passages.
In accordance with other objectives I have been able to optimize
the thickness of insulation surrounding various parts of the
liners, and greatly to simplify the problem of shelf support while
virtually eliminating the need for providing holes through the
liner walls.
SUMMARY OF THE INVENTION
In achievement of the foregoing as well as other objectives, the
invention contemplates a novel method for molding a pair of
adjacent walled cavities as one integral structure of thermoplastic
material, and for defining fluid passages therebetween. In the
practice of this method, I utilize the steps of heating said walled
structures to soften the same, forming said softened structures
over mold means including protrusions extendable into the structure
a distance sufficient to cause predetermined areas of the softened
thermoplastic material to engage one another, and then piercing the
engaged areas to form the passages. The invention further
contemplates novel features of construction of such walled
structures, including passages made according to the above
described method and novel wall configuration.
The manner in which the foregoing as well as other objectives and
advantages of the invention may best be achieved will be understood
from a consideration of the following description, taken in light
of the accompanying drawing.
BRIEF DESCRIPTION OF THE DRAWING
FIG. 1 is an elevational showing of refrigerator cabinet structure
of one type embodying a pair of compartment liners made in
accordance with the invention, and with the doors removed for
convenience of illustration;
FIG. 2 is a sectional showing of the cabinet structure taken
generally along the line indicated by arrows 2--2 applied to FIG.
1;
FIG. 3 is a perspective showing of a portion of the refrigerator
structure seen in FIGS. 1 and 2, illustrating the inner passages
thereof made in accordance with the method contemplated by the
present invention;
FIG. 4 is a sectional-elevational view of mold apparatus for
fabricating the compartment liners of the cabinet seen in FIGS. 1
to 3, and in accordance with the method contemplated by the present
invention;
FIGS. 5, 6 and 7 are further showings of apparatus seen in FIG. 4,
and illustrating operational features thereof;
FIG. 8 is an elevational showing of refrigerator cabinet
construction of another type and made in accordance with the
invention, the cabinet being shown with the door removed;
FIG. 9 is a sectional showing of the cabinet seen in FIG. 8, the
view being taken generally along the line indicated by arrows 9--9
applied to FIG. 8.
FIG. 10 is a showing of apparatus similar to that seen in FIGS. 4
to 7, and illustrating method steps used in the fabrication of the
liner portion of the apparatus seen in FIGS. 8 and 9, as it would
be seen in section along the lines indicated by arrows 10--10
applied to FIG. 8.
FIGS. 11 and 12 are illustrations of further apparatus used in the
fabrication of the above mentioned liners.
DESCRIPTION OF THE PREFERRED PRACTICE AND EMBODIMENTS OF THE
INVENTION
With reference to FIGS. 1 and 2, the illustrated refrigerator
cabinet 10 has a pair of compartments having unidirectionally
presented openings, and defined by a pair of liner sections 11 and
12. The liner sections are made of thermoplastic material, and, in
accordance with the general teaching of the Houghton inventions,
are molded as an integral structure from a single flat sheet of
such material. Thermal insulation designated generally by the
numeral 13, and which may for example be of the foam type, fills
the spaces between the confronting walls of liner sections 11 and
12, and between the outer walls of the same sections and the walls
of outer shell 14 of cabinet 10. It will be understood, of course,
that other well known suitable types of thermal insulation may be
used.
The refrigerating unit is conventional, comprising a compressor 15,
condenser 16, and an evaporator 17 connected in the usual series
flow circuit by suitable conduit means (not shown). Evaporator 17
is conveniently located in the recessed portion 21 of upper liner
section 11, and a partition 22 includes a horizontal section that
extends over the recess and the evaporator. The horizontal section
of partition 22 is provided with front air passages 23, and a
vertical section 22a of the partition is spaced from the top and
rear walls of liner section 11 as shown. Air moved by a blower 24
disposed in the rear, scroll shaped portion 20 of recess 21 is
caused to flow into the freezer storage compartment defined by
liner section 11, through the space between the liner and partition
22a, whence it returns to the region of evaporator 17 through front
passages 23. The lower food storage compartment, defined by liner
section 12, is cooled by air caused to move from the compartment
through passages 25, over evaporator 17, thence back into the
compartment through a passage 30 extending between the wall of
scroll 20 and the upper horizontal wall of liner 12. Recess 21
includes wall portions 11a, 11b that are set in a predetermined
distance which effectively provides a thickened insulation section
in the region of evaporator 17, thereby improving the thermal
performance of the refrigerator. Recess 21 also serves as a drain
trough or sump for the evaporator, and a drain opening may be
provided in said sump by molding or by separate installation.
The method contemplated by this invention readily accommodates
formation of the communicating air passages 25 and 30 (see also
FIG. 3) between the upper and lower refrigerator compartments, and
which passages accommodate the above described air movement.
In carrying out the method contemplated by the invention, use is
made of apparatus of the general type disclosed and claimed in the
referenced copending applications. Such apparatus includes, and
first with reference to FIG. 4, an open top, generally box-shaped
chamber 26 having a pair of sub-sections 27 and 28, each separated
from the other by a partition 29, and each ported at 31 and 32,
respectively, to suitable vacuum producing mechanism of
conventional design (not shown). A clamping ring 33 closely
surrounds the upper rim of vacuum chamber 26, and is constructed
and arranged to clamp in place a heat-softened sheet of
thermoplastic material M that has been urged by an assist plug 35
onto a pair of vented mold members 37 and 38 shaped in
correspondence with the shape of the interior of the food
compartment liners.
Although the molding apparatus used in this invention has in common
with the referenced disclosures the feature of relative pivotation
between mold members 37 and 38, that feature need not be described
herein for an understanding of the present invention. Only those
common features that also form part of the present invention will
be described.
The left-hand mold 37 includes an auxiliary mold section 42 that is
extensible from the retracted position thereof illustrated in FIGS.
4 and 7 to the extended positions illustrated in FIGS. 5 and 6. In
especial accordance with the invention, and for reasons that will
be more fully appreciated from what follows, confronting spaced
surface 59 and protrusions 60 are provided on molds 37 and 38,
respectively.
Movements of auxiliary mold section 42 are affored by runners 44 on
mold 37 slidably interengaged with corresponding grooves (not
shown) on base portion 42a of the auxiliary mold section. Means for
moving auxiliary mold section 42 includes a pair of links 46, only
one of which is shown, each pinned to the mold section at 47 and to
a pair of spaced bell cranks 48 that are pivoted at 49 to mold 37.
Bell cranks 48, only one of which is illustrated for the sake of
convenience, further are pinned to the piston rod of a pneumatic
cylinder 50 pivoted at 52 to mold 37. The construction and
arrangement is such that extension of piston rod 51 will rock crank
48 about its pivot 49 in a counterclockwise direction to move link
46 to the left and retract auxiliary mold section 42 to the
position shown in FIGS. 4 and 7. Conversely, retraction of rod 51
rocks crank 48 about pivot 49 in a clockwise direction, moving link
46 to the right and extending mold section 42 to the position shown
in FIGS. 5 and 6. As will be appreciated from FIG. 5, auxiliary
mold section 42 is projected into engagement with that portion of
sheet M that extends over left-hand mold 37, after the portion of
the same sheet M extending over the right-hand mold 38 has been
vacuum-formed over the latter mold, and its protrusion 60, by
drawing a vacuum in chamber 28 through port 32. Projection of
auxiliary mold section 42 to its fully extended position causes
regions of the heat-softened sheet overlying surfaces 59 and
protrusions 60 to engage and thereafter permanently adhere to one
another.
In further particular accordance with the invention, a second
extensible and retractible auxiliary mold member 61 is carried by
mold section 38, and provides, in its extended position seen in
FIGS. 5 and 6, for molding the air passage means 30 seen in FIGS. 2
and 3. Mold member 61 is generally retangular in cross section and
is slidable from retracted positions shown in FIGS. 4 and 7 through
suitable aperture means (not shown) within the wall of mold member
38. The inner, or right-hand, end of mold member 61 is carried by
rod 62 of a pneumatic cylinder 63 mounted within mold member 38.
The construction and arrangement is such that operation of rod 62
to extended position moves mold member 61 to its extended position
(FIGS. 5 and 6). Conversely, operation to retract rod 62 also
retracts mold member 62 (FIGS. 4 and 7).
Considering in detail the preferred sequence of operation of the
mold members, and with reference to FIG. 4, heat softened sheet M
is urged onto molds 37 and 38 by movement of assist plug 35 to the
position shown, and while auxiliary mold sections 42 and 61 are in
their retracted positions.
Assist plug 35 is then moved away from and clear of the molds to
the position shown in FIG. 5. Auxiliary mold section 61 is then
extended, urging its confronting portion of flat overlying sheet M
into engagement with a corresponding portion of the same sheet
overlying auxiliary mold section 42. This is followed by drawing a
vacuum in chamber 28 by way of port 32, whereupon the right-hand
portion of heat softened sheet M is caused to conform to mold
member 38 and its extended auxiliary section 61.
With reference to FIG. 6, and considering the molding sequence in
further detail, a vacuum is drawn in left-hand chamber 27 by way of
port 31, while auxiliary mold section 42 is extended. The portion
of sheet M overlying mold 37 and its auxiliary section 42
accordingly is drawn into conformity with the latter and portions
of sheet M overlying surface 59 and confronting protrusions 60
engage and adhere to one another.
With reference to FIG. 7, auxiliary mold sections 42 and 61 are
then moved from extended to retracted positions, and the liner
sections molded from sheet M are ready for stripping as a unit from
the molds.
It should be understood that while auxiliary mold section 61 is
shown as two-dimensional, it will have a cross sectional dimension
corresponding to that of air passage 30 as best seen in FIG. 3.
The regions of adherence of the above described molded liner
sections are then pierced in a suitable manner, for example by
punching as is shown somewhat diagrammatically in FIGS. 11 and 12.
Conveniently, and by way of illustration, suitable apparatus may
include a punch 64 and die 65 of desired cross-sectional shape and
operable to remove liner sections 11c, 12a in completion of air
passage 30. It will be understood that passages 25 are completed in
the same manner, using a similar punch of suitable shape. As a
result of the punching operation, there are formed lined, generally
tubular, fluid passages or ducts 25 and 30 that are sealed with
respect to later provided insulation 13 through which the ducts
pass.
It will be further appreciated from a consideration of FIGS. 8, 9,
and 10 that the invention lends itself to fabrication of air
passage means in refrigerator cabinet structure 70 of the
side-by-side type. With more detailed reference to FIG. 8, cabinet
70 has a pair of compartments having unidirectionally presented
openings, and defined by a pair of liner sections 71 and 72. The
liner sections are made of thermoplastic material, and, in especial
accordance with the invention, are molded as an integral structure
from a single flat sheet of such material. Thermal insulation
designated generally by the numeral 73 fills the spaces between the
confronting walls of liner sections 71 and 72, and between the
outer walls of the same sections and the walls of the outer shell
74 of cabinet 70.
The refrigerating unit is conventional, comprising a compressor 75,
a condensor (not shown) and an evaporator 77 connected in the usual
series flow circuit by suitable conduit means. Evaporator 77 is
conveniently located in the lower rear region of left-hand liner
section 71, and a vertical partition 78 includes a lower section
that extends over the evaporator and an upper section that extends
over a fan 80. The upper section of partition 78 is provided with
air grilles 79 over the fan 80.
Air moved by fan 80 is caused to flow through grilles 79 into the
freezer storage compartment defined by liner section 71, through
the space between the liner and the lower section of partition 78,
thence returning to the region of evaporator 77. The right-hand
food storage compartment, defined by liner section 72, is cooled by
air caused to move from the compartment through lower passage 81,
over evaporator 77, and thence back into the compartment through an
upper passage 82 extending between the compartments.
As will be understood from FIG. 10, the method contemplated by the
invention readily accommodates formation of the communicating air
passages 82 and 81 between the side-by-side refrigerator
compartments, and which passages accommodate the above described
air movement. The method is carried out using apparatus similar to
that used in forming liners 11 and 12, as explained in connection
with FIGS. 3, 4, 5 and 6. Apparatus includes vacuum chambers 83,
83a ported at 84, 84a to vacuum producing devices. A clamping ring
85 is positioned to clamp the heat-softened sheet 86 that has been
urged by an assist plug (not shown) onto a pair of vented,
pivotally mounted mold members 87 and 88 shaped in correspondence
with the shape of the interior of the desired food compartment
liners.
The right-hand mold member 88 includes a pair of auxiliary mold
sections 89 and 90, of generally elongate and generally circular
cross section, respectively, which are mounted for movement from
retracted positions to extended positions as shown in FIG. 10.
Movements of mold sections 89 and 90 are provided by pneumatic
cylinders 91 and 92, respectively.
In forming liners 71 and 72 a heat softened sheet 86 is urged onto
mold members 87 and 88, and a vacuum drawn through port 84 to
conform sheet 86 with mold member 87. Auxiliary mold sections 89
and 90 are then moved to the illustrated extended position, and a
vacuum is drawn through port 84a, causing sheet 86 to conform with
mold member 88 and its auxiliary mold sections 89 and 90. After a
period of cooling, mold sections 89 and 90 are moved to retracted
position, and the integrally formed liner sections and
interconnecting air passages are removed from the mold members.
The formed air passages are then punched through, in accordance
with the showing of FIGS. 11 and 12.
A further feature of the invention is that the method contemplated
thereby makes possible the molding two liner compartments 71 and 72
of various relative sizes and shapes. For example, and with
reference to FIG. 8, the lower side walls of left-hand compartment
liner 71 are formed inwardly as seen at 71a and 71b and thus
accommodate thickened insulated wall sections to either side of the
vertically extending evaporator coil 77 positioned against the
lower rear wall of liner 71. Below the evaporator coil 77, a drain
trough 71c is molded into a lower rear section of the liner 71,
using auxiliary mold means of the type used to form recess 21 in
FIG. 3.
A number of advantages derive from both embodiments of the
disclosed invention, in that two separate compartments, and
interconnecting air passages, are integrally connected to
accommodate their installation as a unit in the outer shell of a
refrigerator. Further, by way of advantage, one compartment is very
accurately registered with respect to the other so that predictable
temperature differentials can be maintained therebetween, with
resultant improvements in operating performance. Further control of
temperatures is achieved through selectivity of insulation
thickness (see 11a, 11b, FIG. 3, and 71a, 71b, FIGS. 8-10) in the
region of the evaporator, which thickness may be selectively varied
simply by changing the contours of the molds in the desired
regions. Still further, condensate drain troughs (see 21, FIG. 3,
and 71c, FIGS. 8, 9), shelf supports (see 71d, FIGS. 8, 9) and the
like may be formed by appropriately shaping surfaces of the
molds.
* * * * *