Refrigerator Cabinet Structure

Abstract

A refrigerator cabinet structure is provided in which a closed-cell foamed seal is utilized as a seal between the rear panel and outer wrapper of the refrigerator cabinet at the rear and an open-cell foamed seal is utilized between the outer wrapper and inner liner at the front of the refrigerator cabinet. The space between the inner liner, outer wrapper and rear panel is then filled with a conventional foamed plastic insulating material with the open cell foam seal at the front of the refrigerator cabinet permitting the escape of air as the foamed plastic expands into the space between the outer wrapper, inner liner and rear panel.

Description

BACKGROUND OF THE INVENTION

1. Field of the Invention:

This invention relates to refrigerator apparatus and, more particularly, relates to a cabinet structure for a refrigerator.

2. Description of the Prior Art:

The use of foamed celled insulating slabs between the walls of a refrigerator cabinet are old and well known such, for example, being shown in U.S. Pat. Nos. 3,112,624 and 3,401,997. However, in each of these patents the refrigerator cabinet is provided with a specialized sealing arrangement at the joints between the rear panel and outer wrapper and inner liner and outer wrapper. More specifically, in U.S. Pat. No. 3,112,624 a high density substantially impervious closed cell plastic foam or resin is coated on the aforementioned joints prior to the final major foaming in the space between these walls. Thus, the foaming operator for the refrigerator of this patent requires at least a two step process involving the use of a high density coating material at the effected joints and then a further foaming of a polyurethane foam to fill the remainder of the volume formed between the outer wrapper, inner liner and rear panel. Further, it would appear that the seals formed by the substantially impervious closed cell plastic foam at the joints between the three structural elements would prevent the escape of air as the final foaming operations occurs so that apertures would have to be formed in the walls of the outer wrapper and rear panel to permit the escape of air during the final foaming operation. U.S. Pat. No. 3,401,997 does not require the use of a coating of impervious closed cell plastic foam or resin at the joints between the inner wrapper panel and outer wrapper. However, the joints between these elements are formed in a very tight relationship by the use of tongue and groove assemblies between these elements so that, during foaming, the escape of air would be prevented from the space formed between the rear panel, outer wrapper and inner liner so that escape apertures would have to be provided in these members which would normally be sealed later so as to yield an attractive outer appearance to the refrigerator cabinet.

The use of the coating operation of U.S. Pat. No. 3,122,624 or the tightly formed tongue and groove joints of U.S. Pat. No. 3,401,997 and the addition of escape apertures to the cabinets in both of these patents necessitates additional manufacturing steps and accrued costs therefrom. Accordingly, it would be advantageous to provide a refrigerator cabinet assembly which did not require extremely tightly formed joints between the mating parts of the rear panel, outer wrapper and inner liner and also to provide a refrigerator cabinet which accommodates, in its make-up, means to permit the exit of air trapped between the rear panel inner liner and outer wrapper during the foaming operation.

SUMMARY OF THE INVENTION

The invention provides an outer wrapper for the refrigerator cabinet which has flanges formed at both its front and rear edges. The flange formed at the rear of the outer wrapper is provided with a closed cell substantially impervious gasket which is inserted within the open-faced U formed by the flange, prior to the insertion of the rear panel. Insertion of the rear panel assembly into this flange then compresses the substantially impervious plastic gasket to a great extent so that confronting faces formed on the outer wrapper and the rear panel are closely continuous. The flange arrangement formed at the front of the outer wrapper also is provided with a gasket material but, in this case, the gasket material is an open cell plastic liner which is not impervious to the passage of gasses therethrough. After positioning of this pervious plastic gasket within the open face U formed by the front flange of the outer wrapper, the inner liner is inserted within this flange so that its most outward projection slides along one face of the flange completely compressing the pervious cell gasket in this are. The remainder of the pervious gasket is also compressed to a slight degree but an insufficient degree to compress it so that it becomes impervious.

Because of the use of an impervious gasket at the rear of the outer wrapper and a pervious gasket at the front of outer wrapper, provision is made for passing the trapped air outwardly between the outer wrapper and an inner liner during the foaming operation so that the foamed insulation substantially fills the cavity formed between the outer wrapper, rear panel and inner liner. It is contemplated that the refrigerator cabinet assembly will be foamed with the rear panel lying face down, with foaming occurring upwardly therefrom so that as the foam moves upwardly between the inner liner and the outer wrapper, air may easily escape through the pervious cell gasket disposed at the front of the outer wrapper. At the same time, then, the total pressure retention requirements of the pervious cell gasket is somewhat lessened so that there is very small chance for the foam, as it foams inwardly within the refrigerator cabinet, to suffer any blow-through with a consequent deposit of unsightly foamed material on the outer surfaces of the refrigerator cabinet. Foaming, however, may also be downwardly between the outer wrapper and inner liner but the results of such a method is not nearly as good as that when the foaming is upwardly between these two members.

DRAWING DESCRIPTION

FIG. 1 is a front view of a refrigerator cabinet embodying the principles of this invention;

FIG. 2 is a partial cross-sectional view taken generally on line II--II of FIG. 1; and

FIG. 3 is a somewhat schematic showing of the manner of foaming the instant invention.

DESCRIPTION OF THE PREFERRED EMBODIMENT

According to the principles of my invention, a refrigerator 10 is provided which includes a refrigerator cabinet portion 12 and a lower, base portion 14 disposed in supporting relationship to the refrigerator cabinet portion. The front of the refrigerator cabinet 12 is closed by a refrigerator door 16 which may be hinged for outward swinging (not shown) by any conventional arrangement to the refrigerator cabinet 12.

The outer surface of the refrigerator cabinet 12 is formed by an outer wrapper 18 which is generally U-shaped in configuration, with the bight portion of the U being disposed as a top panel 19 for the refrigerator and the legs of the U forming the pair of side panels 21 for the refrigerator. A rear panel 20 is formed in a right angle so as to provide a rear surface 22 and bottom panel 24 for the refrigerator 10.

In order to provide a closed insulated volume for the refrigerator cabinet 12, an inner liner 26 (FIG. 2) in the conventional form of a generally open box shape is disposed within the enclosure formed by the outer wrapper and rear panel of the refrigerator cabinet 12, with this inner liner forming the entire inner surface of refrigerator cabinet and on which are disposed the shelves or the like (not shown) which support any food or food articles being cooled within the refrigerator 10.

As is seen in FIG. 2, the outer wrapper 18 includes adjacent its rearward periphery and adjacent its forward periphery a flange, the flange 28 being the rearward flange and the flange 29 being the forward flange. Each of these flanges forms an inwardly opening U-shape, with the formation of this U-shape being provided by each of the ends of the outer wrapper 18 being bent backwardly against itself and then at a right angle to the bent back portion and then again at another right angle to provide a portion parallel to the bent back portion. The bent back portion of the outer wrapper 18 along with the major extent of the outer wrapper 18 in this area provides opposed confronting surfaces 30 and 32 at the rearward extreme of the outer wrapper 18 and opposed confronting surfaces 34 and 36 at the forward extreme of the outer wrapper 18. Extensions 38 and 40 are provided by the bending of outer wrapper 18 at right angles to itself so as to form the "bight" portions of the U-shape for the flanges 28 and 29 which open inwardly relative to the refrigerator cabinet 12. The U-shaped flange shape is completed by portions 42 and 44 which extend at right angles to the portions 38 and 40 respectively, and substantial parallel to the surfaces 32 and 36 respectively. The surface 36 and portions 40 and 44 thereby complete the U-shape construction of each of the flanges 28, 29 with these flanges completed by an angularly extending portion 46 that is integral with the surface 32 and portions 38 and 42. The angular extending portion 46 forms a convenient lead-in entrance angle for the assembly of the components which are inserted within the flanges 28 and 29. These flanges, then, provide the attachment means for the insertion and mounting of the rear panel and inner liner of the refrigerator cabinet 12.

In order to provide a sealing arrangement between the outer wrapper 18 and rear panel 20, a closed cell, impervious foam seal 48, formed from a substantially dense, closed cell flexible polyurethane or the like, is provided, with this seal being inserted within the U-shaped opening formed by the flange 28 and abutting against the portion 38 so as to be so disposed inwardly, as far as possible relative to the flange 28. An adhesive (not shown) may be utilized on the outer surface of the closed cell seal so that it is positively located relative to the flange 28 prior to the assembly of the rear panel 20 with the outer wrapper 18.

A relatively pervious, open cell foam seal 50, formed from an open cell polyurethane or fiberglass is provided at the front of the refrigerator cabinet 12 and is disposed within the flange 29, with this seal also provided, if desired, with an adhesive (not shown) so as to be nestingly held within the flange 29 against the portion 44 until the inner liner 26 is assembled with the outer wrapper 18.

After assembly of the seals 48 and 50 to the outer wrapper 18 of the refrigerator cabinet 12, the outer wrapper 18 is formed into the U-shape and the rear panel 20 and inner liner 26 are mounted thereon. More specifically, the rear surface 22 of rear panel 20 is provided with a right angle bend portion 52 along its sides, with this portion dimensioned so as to be substantially coextensive in length and width as the portion 38 that forms the bight of flange 28. As illustrated in FIG. 2, it can be seen that the right angle portion 52 is disposed in compressing relationship relative to the foam seal 48. The thickness of the foam seal in its assembled condition has been exaggerated for the purposes of illustration. It should be specifically pointed out that the insertion of the rear panel 20 within the U-shaped flange 28 substantially compresses the foam seal 48 so that it completely fills the open U-shape of flange 28 from front to back and from side to side and is compressed to a great extent between the portion 38 and right angle portion 52 so that these portions lay very closely adjacent to each other, with the same being very evident from a drawing made to scale.

The inner liner 26 is assembled in the U-shaped flange 29 in a somewhat similar manner to the assemblage of the rear panel 20 to the flange 28; however, in order to assure a proper secure fit between it and the outer wrapper 18, the inner liner is provided with a double right-angle bend at its outward termination to form adjoining portions 54 and 56. The portion 54 extends substantially perpendicularly relative to the opened U-form of the flange 29 and the portion 56 integral and adjoining to it extends substantially parallel to the portion 44 of the U-shaped flange 29. The pervious flange seal 50 is generally square, in cross section, prior to its compression by the inner liner 26 when it is first assembled within the open U-formed by the flange 29. However, insertion of the portions 54 and 56 of the inner liner 26 within this open U-shaped flange causes the portion 56 to penetrate inwardly compressing the foam seal 50 in a conforming relationship so that in a compressed condition and with the liner 26 fully assembled with the outer wrapper 18, the foam seal 50 has a stepped configuration along one of its sides. This particular seal is not compressed to as great a degree as the compression of the seal 48 so that, as illustrated, in FIG. 2, the seal 50 has assumed its general, final configuration. It should be apparent that the foam seal 48 will provide a substantially air-tight seal for the rear of the refrigerator cabinet 12 but that the foam seal 50, disposed at the front of the refrigerator cabinet 12, because of its porosity and permeability, will permit the egress of air therefrom. This physical characteristic of the open cell seal 50 is advantageously utilized in the instant invention during the foaming process.

The refrigerator cabinet 12 is assembled (FIG. 3) by first mounting the seals 48 and 50 within their U-shaped flanges 28 and 29, then forming the outer liner 18 to its final configuration and then placing the inner liner 26 within the U-shaped flange 29 and the rear panel 20 within the U-shaped flange 28. This assembly operation substantially compresses the closed cell seal 48 nested in the flange 28 and provides an air tight joint in this area. At the same time, the seal 50 is slightly compressed providing a pervious seal through which air may pass during the foaming operation. The refrigerators are disposed with the rear panel 20 downwardly and foaming through this panel occurs by means of, for example, nozzles 62 with the foam 58 moving upwardly between the inner liner 26 and the outer wrapper 18 as it foams, forcing the air contained within the closed volume formed by the outer wrapper 18, rear panel 20 and inner liner 26 outwardly through the foam seal 50. Because of this upward foaming, the open cell seal 50 is never subjected to extremely high foaming pressures by the foam 58, also a polyurethane, so it provides an adequate and satisfactory seal to prevent the extrusion of foam outwardly thereof so that very little clean-up, if any, is required after the foaming operation for the refrigerator cabinet 12.

Because of the relatively high temperature and moisture content occurring in the area such as a kitchen where the refrigerator 10 is maintained, the foam seal 50 could, if exposed thereto, pick-up high temperature and moisture laden air and this air could then be transmitted into the foamed plastic 58. In such case, the insulation efficiency of the foamed plastic 58 would be lessened. These undesirable results are prevented, however, by the fact that a door flange 60 of soft rubber-like material is provided for attachment to the door 16 so that it extends entirely around its periphery. With the door flange 60 abutting the outer wrapper 18 outwardly of the location of the pervious foamed plastic gasket 50, this gasket, at worst, is subjected only to the temperature and moisture conditions of the environment within the refrigerator 10.

It should be clear to one skilled in the art that the described refrigerator cabinet provides all the advantages set out for it and that many modifications could be made to it which would still fall within the spirit of the invention as described.

Claims

What is claimed is:

1. A refrigerator cabinet including;

a. an outer wrapper,

b. a rear panel mounted on said outer wrapper,

c. an inner liner disposed within said outer wrapper,

d. flange means carried by said outer wrapper for receiving portions of said rear panel and inner liner,

e. impervious flange sealing means disposed in said flange means receiving portions of said rear panel, and

f. pervious flange sealing means disposed in said flange means receiving portions of said inner liner.

2. The combination set out in claim 1 wherein;

a. said flange means provides an inwardly opening U-shape for the reception of said portions of said rear panel and inner liner and said impervious and pervious flange sealing means.

3. The combination set out in claim 2 wherein;

a. said portions of said rear panel compressingly maintain said impervious flange sealing means in said flange means receiving portions of said rear panel.

4. The combination set out in claim 2 wherein;

a. said portions of said inner liner compressingly maintain said pervious flange sealing means in said flange means receiving portions of said inner liner.

5. The combination as set out in claim 4 wherein;

a. said flange means is formed at least partly by said outer wrapper being bent backwardly upon itself.

6. The combination as set out in claim 5 wherein;

a. said flange means also includes portions which extend parallel to the major extent of said outer wrapper but spacedly displaced from said bent back portion.

7. A refrigerator cabinet including;

a. an outer wrapper,

b. a rear panel,

c. an inner liner,

d. flange means carried by said outer wrapper for receiving portions of said rear panel and inner liner,

e. impervious flange sealing means disposed in said flange means receiving portions of said real panel,

f. pervious flange sealing means disposed in said flange means receiving portions of said inner liner,

g. said flange means provides an inwardly opening U-shape for the reception of said portions of said rear panel and inner liner,

h. said portions of said inner liner compressingly maintain said pervious flange sealing means in said flange means receiving portions of said inner liner,

i. said flange means formed at least partly by said outer wrapper being bent backwardly upon itself,

j. said flange means also including portions which extend parallel to the major extent of said outer wrapper but spacedly displaced from said bent back portion, and

k. said flange means also including portions which extend angularly relative to said spacedly displaced portions for providing a lead-in during assembly of said refrigerator cabinet.