CN1269879A - 箱体及其部件和制造方法 - Google Patents

箱体及其部件和制造方法 Download PDF

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Publication number
CN1269879A
CN1269879A CN98808957A CN98808957A CN1269879A CN 1269879 A CN1269879 A CN 1269879A CN 98808957 A CN98808957 A CN 98808957A CN 98808957 A CN98808957 A CN 98808957A CN 1269879 A CN1269879 A CN 1269879A
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CN
China
Prior art keywords
seam
wall
base
spare
wall spare
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Granted
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CN98808957A
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English (en)
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CN1144009C (zh
Inventor
斯图尔特·沃恩
丹尼尔·威滕－汉娜
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Fisher and Paykel Appliances Ltd
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Fisher and Paykel Ltd
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Publication of CN1269879A publication Critical patent/CN1269879A/zh
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    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C65/00—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor
    • B29C65/02—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor by heating, with or without pressure
    • B29C65/18—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor by heating, with or without pressure using heated tools
    • B29C65/20—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor by heating, with or without pressure using heated tools with direct contact, e.g. using "mirror"
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F25—REFRIGERATION OR COOLING; COMBINED HEATING AND REFRIGERATION SYSTEMS; HEAT PUMP SYSTEMS; MANUFACTURE OR STORAGE OF ICE; LIQUEFACTION SOLIDIFICATION OF GASES
    • F25D—REFRIGERATORS; COLD ROOMS; ICE-BOXES; COOLING OR FREEZING APPARATUS NOT OTHERWISE PROVIDED FOR
    • F25D23/00—General constructional features
    • F25D23/08—Parts formed wholly or mainly of plastics materials
    • A—HUMAN NECESSITIES
    • A61—MEDICAL OR VETERINARY SCIENCE; HYGIENE
    • A61P—SPECIFIC THERAPEUTIC ACTIVITY OF CHEMICAL COMPOUNDS OR MEDICINAL PREPARATIONS
    • A61P29/00—Non-central analgesic, antipyretic or antiinflammatory agents, e.g. antirheumatic agents; Non-steroidal antiinflammatory drugs [NSAID]
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
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    • B29C49/00—Blow-moulding, i.e. blowing a preform or parison to a desired shape within a mould; Apparatus therefor
    • B29C49/02—Combined blow-moulding and manufacture of the preform or the parison
    • B29C49/06905—Using combined techniques for making the preform
    • B29C49/0691—Using combined techniques for making the preform using sheet like material, e.g. sheet blow-moulding from joined sheets
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C51/00—Shaping by thermoforming, i.e. shaping sheets or sheet like preforms after heating, e.g. shaping sheets in matched moulds or by deep-drawing; Apparatus therefor
    • B29C51/26—Component parts, details or accessories; Auxiliary operations
    • B29C51/266—Auxiliary operations after the thermoforming operation
    • B29C51/267—Two sheets being thermoformed in separate mould parts and joined together while still in the mould
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
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    • B29C53/00—Shaping by bending, folding, twisting, straightening or flattening; Apparatus therefor
    • B29C53/02—Bending or folding
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    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
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    • B29C53/00—Shaping by bending, folding, twisting, straightening or flattening; Apparatus therefor
    • B29C53/80—Component parts, details or accessories; Auxiliary operations
    • B29C53/84—Heating or cooling
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
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    • B29C66/004—Preventing sticking together, e.g. of some areas of the parts to be joined
    • B29C66/0042—Preventing sticking together, e.g. of some areas of the parts to be joined of the joining tool and the parts to be joined
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    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
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    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
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    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
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    • B29C66/00—General aspects of processes or apparatus for joining preformed parts
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    • B29C66/05—Particular design of joint configurations
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    • B29C66/1162—Single bevel to bevel joints, e.g. mitre joints
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    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C66/00—General aspects of processes or apparatus for joining preformed parts
    • B29C66/01—General aspects dealing with the joint area or with the area to be joined
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    • B29C66/122—Joint cross-sections combining only two joint-segments, i.e. one of the parts to be joined comprising only two joint-segments in the joint cross-section
    • B29C66/1222—Joint cross-sections combining only two joint-segments, i.e. one of the parts to be joined comprising only two joint-segments in the joint cross-section comprising at least a lapped joint-segment
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C66/00—General aspects of processes or apparatus for joining preformed parts
    • B29C66/01—General aspects dealing with the joint area or with the area to be joined
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    • B29C66/1224—Joint cross-sections combining only two joint-segments, i.e. one of the parts to be joined comprising only two joint-segments in the joint cross-section comprising at least a butt joint-segment
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C66/00—General aspects of processes or apparatus for joining preformed parts
    • B29C66/40—General aspects of joining substantially flat articles, e.g. plates, sheets or web-like materials; Making flat seams in tubular or hollow articles; Joining single elements to substantially flat surfaces
    • B29C66/41—Joining substantially flat articles ; Making flat seams in tubular or hollow articles
    • B29C66/43—Joining a relatively small portion of the surface of said articles
    • B29C66/432—Joining a relatively small portion of the surface of said articles for making tubular articles or closed loops, e.g. by joining several sheets ; for making hollow articles or hollow preforms
    • B29C66/4326—Joining a relatively small portion of the surface of said articles for making tubular articles or closed loops, e.g. by joining several sheets ; for making hollow articles or hollow preforms for making hollow articles or hollow-preforms, e.g. half-shells
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
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    • B29C66/40—General aspects of joining substantially flat articles, e.g. plates, sheets or web-like materials; Making flat seams in tubular or hollow articles; Joining single elements to substantially flat surfaces
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    • B29C66/43—Joining a relatively small portion of the surface of said articles
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    • B29C66/43421—Joining substantially flat articles for forming corner connections, e.g. for making V-shaped pieces with a right angle, e.g. for making L-shaped pieces
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    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
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    • B29C66/8141—General aspects of the pressing elements, i.e. the elements applying pressure on the parts to be joined in the area to be joined, e.g. the welding jaws or clamps characterised by the design of the pressing elements, e.g. of the welding jaws or clamps characterised by the surface geometry of the part of the pressing elements, e.g. welding jaws or clamps, coming into contact with the parts to be joined
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    • B29C66/30223—Particular design of joint configurations the area to be joined comprising melt initiators said melt initiators being integral with at least one of the parts to be joined said melt initiators being rib-like
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    • B29K2105/04—Condition, form or state of moulded material or of the material to be shaped cellular or porous
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    • F25D—REFRIGERATORS; COLD ROOMS; ICE-BOXES; COOLING OR FREEZING APPARATUS NOT OTHERWISE PROVIDED FOR
    • F25D2201/00—Insulation
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    • F25D2201/12—Insulation with respect to heat using an insulating packing material
    • F25D2201/126—Insulation with respect to heat using an insulating packing material of cellular type

Abstract

一种用双片材热成形板(1)制成的冰箱箱体,该板用接缝(6)划分成多个壁段(8、9、10),双片材(2、3)在接缝处接触。折叠该板形成冰箱箱体的后壁(10)和侧壁(8、9),然后装上顶盖和底座以固定这些壁。各制冷系统部件装在底座上。侧壁(8、9)和后壁(10)靠其顶边和底边(25、30)装在顶盖(20)和底座(21)上的周边凹槽(28、29)中而得以固定。该板的内片材在折叠接缝(6)旁的熔合接触部(65、76)使得这些壁进一步固定。该板最好在仍支撑在热成形模具上时用刚性绝热泡沫塑料填满。接缝(6)最好位于该箱体的后面(61)上、与侧面与后面之间的转角相间距,从而用隐藏的折叠线美化外观。还公开了软化各壁段之间的接缝的一种改进加热器。

Description

箱体及其部件和制造方法
技术领域
本发明涉及箱体、该箱体在装配完成前的部件和制造箱体的方法，特别涉及冰箱的绝热箱体及其制造方法。
现有技术
当前的家用冰箱、特别是箱体的制造通常是用卷边把一热成形塑料内层放置在一成形钢外层上，该成形钢外层可先涂漆，也可后涂漆。一钢或塑料底座与一相似材料的后板一起装到该组件的底端和顶端上，从而在内外层之间形成一密封空腔。把该组件放入一支撑该箱体的各壁的夹具中，同时绝热材料被注入该空腔后膨胀。这种制造过程还需密封各部件之间的接缝，以防止膨胀的泡沫材料漏出。
美国专利4,580,852示出包括这种箱体的一冰箱。这种结构和制造方法的缺点是部件数多、制造工艺复杂、因此制造成本高。此外费时费工。
在转让给Whirlpool公司的美国专利5,374,118所示的一冰箱箱体中，侧壁和顶壁用双壁热成形制成一体。侧壁和顶壁折叠后一背部装到箱体上使侧壁和顶壁定位。箱体的该背部中装有制冷系统。尽管这种结构较之现有技术有了很大改进，但装有制冷系统的背部占据冰箱的很大空间，背部与冰箱箱体的连接和密封也很困难。
本发明概述
因此本发明的一个目的是提供一种箱体和/或该箱体的各部件和/或该箱体的制造方法，从而向克服上述缺点的方向迈出一步，或至少为公众提供一种有用的选择。
本发明的一个方面涉及一种冰箱箱体，包括：
一双壁绝热塑料件，其由多个细长接缝划分成三个或三个以上壁段，这些壁段顺序地并排布置，在这些接缝处所述双壁接触，所述双壁绝热塑料件在所述接缝处折叠，从而所述壁段顺序地形成一箱体的三个或三个以上的侧壁，这些侧壁在所述细长接缝处连接，所述各侧壁之间界定一制冷空间，
一与所述壁件的顶边连接、从而使得所述壁件保持所述折叠形状的顶盖，所述顶盖封闭所述制冷空间的顶端，
一与所述壁件底边连接、从而使得所述壁件保持所述折叠形状的底座，所述底座直接或间接地支撑所述制冷系统的机械部件，以及
与所述底座制成一体或分开制造的底部装置，用来封闭所述制冷室的底端。
本发明的另一方面涉及一冰箱，包括上述一冰箱箱体；装在所述冰箱箱体上、封闭所述制冷空间的正面、从而封闭整个所述制冷空间的一门和一使所述制冷空间制冷的制冷系统，所述制冷系统的至少一部分装在所述底座上。
本发明的另一方面涉及一种冰箱箱体制造方法，包括下列步骤：
(a)热成形一双壁绝热塑料件，其由多个细长接缝划分成三个或三个以上壁段，在这些接缝处所述双壁接触，
(b)沿所述各接缝折叠所述塑料壁件，形成一箱体的三个或三个以上的侧壁，这些侧壁在所述各细长接缝处连接，所述各侧壁之间界定一制冷空间，以及
(c)把一顶盖装在所述箱体上，使得所述壁件保持所述折叠形状并封闭所述制冷空间的顶端，以及
(d)把一底座装在所述壁件的底边上，使得所述壁件的底边保持所述折叠形状。
本发明的另一方面涉及用按上述一个段落或多个段落所述方法制造的一种冰箱箱体。
本发明的另一个方面涉及一种箱体，包括：
一双壁绝热塑料件，其由多个细长接缝划分为三个或三个以上壁段，这些壁段顺序地并排布置，在这些接缝处所述双壁接触，所述双壁绝热塑料件在所述接缝处折叠，从而所述壁段顺序地形成一箱体的三个或三个以上的侧壁，这些侧壁在所述细长接缝处连接，以及
一顶盖或底盖，它有一内表面和一外表面，其内表面上沿其至少两边或靠近其周边有一凹槽，所述折叠的塑料壁件的顶边和/或底边装配在所述凹槽中，所述凹槽使得所述壁件保持所述折叠形状。
本发明的另一方面涉及一用具的箱体，包括一用双片材热成形制成的壁件，所述壁件包括多张板，所述多张板由一个或多个接合边互相连接，其中，所述双片材接触而形成一接缝，在所述用具中所述壁件沿一个或多个所述接缝折叠，从而所述多张板形成所述用具的多个壁，作为一组，所述壁件在起初热成形时结构不同，从而所述折叠接缝中的一个或多个接缝不与所述用具的壁之间的转角重合，这些壁与由各折叠接缝连接的各板对应。
本发明的另一方面涉及一用具的箱体，包括一用双片材热成形制成的壁件，所述壁件包括多张板，所述多张板由一个或多个接合边互相连接，其中，所述双片材接触而形成一接缝，在所述用具中所述壁件沿一个或多个所述接缝折叠，从而所述多张板形成所述用具的多个壁，该用具的整体构型与所述壁件在起初热成形时不同，在至少一个所述接缝处，所述双壁塑料件有一面向内片材和一面向外片材，在所述接缝处这样形成所述壁件，即在所述折叠状态下所述面向内片材接触本身，该面向内片材在所述接缝两边、与所述接缝相间距的部分互相接触，所述接触部互相熔合在一起。
本发明的另一个方面涉及一用双片材热成形制成的壁件，包括一个或多个接缝，所述双片材在接缝处接触，所述壁件可在一个或多个所述接缝处折叠而形成多个壁，其特征在于，至少一个所述接缝在折叠时转过一定位角；所述双片材中的至少一个所述片材在所述接缝处或大致在所述接缝处在该片材的两表面之间有一过渡，该过渡与所述定位角互补，从而当所述接缝在折叠时转过所述定位角时，所述两表面穿过所述接缝而连续。
本发明的另一个方面涉及制备一双片材热成形壁件的设备，该壁件包括一个或多个接缝，所述壁件在这些接缝处折叠时所述壁件在所述接缝处的两内表面抵靠在一起，该设备包括：一传热头，该传热头有一沿所述待折叠接缝接触该接缝的加热面；加热所述传热头的装置，所述传热头支撑在一支撑装置上，该支撑装置与所述壁件的一支撑装置一起，使所述加热面与所述接缝接触，从而把热量从所述传热头传到所述接缝上，从而软化所述接缝，以便折叠。
本发明的另一个方面涉及本文结合附图1-5所述和所示的一种冰箱箱体。
本发明的另一个方面涉及本文结合附图6和7所述和所示的冰箱箱体。
本发明的另一个方面涉及本文结合附图所述和所示的一种冰箱箱体制造方法。
本发明的另一个方面涉及一用具的箱体，该箱体包括本文结合图9所述和所示的转角结构。
本发明领域普通技术人员不难看出，本发明的种种结构改变、种种完全不同的实施例和应用都在由权利要求限定的本发明范围内。因此以下所公开的内容和说明只是例示性的而非限制性的。
附图的简要说明
下面结合附图详述本发明各实施例，附图中：
图1为一用来制造本发明由双片材壁形成的板的热成形模具的端视剖面图，该模具处于合上的结构，
图2为在注入泡沫塑料过程中沿图1模具A-A线剖取的侧视剖面图，
图3为从模具中取出的本发明第一实施例的双片材板的立体图，
图4为刚从模具中取出的该板的一端的剖视立体图，
图5为本发明冰箱箱体组件的分解立体图，
图6为本发明另一实施例的双片材板的立体图，
图7为所述另一实施例的冰箱箱体组件的分解立体图，
图8为本发明双片材板的一部分的俯视剖面图，当折叠成冰箱箱体组件时，形成该冰箱箱体的后壁与一侧壁之间的一转角，此外还示出加热、软化该双片材之一或两片材的一部分的一工具，以及
图9为图8板的一部分形成的冰箱箱体转角的俯视剖面图。
实施本发明的最佳方式
图5示出一冰箱箱体，包括在铰接区6连接成一体的侧壁8、9和一后壁10。如图所示，侧壁8、9和后壁10在铰接区折叠而形成所示的侧壁8、9和后壁10。壁8、9、10用一顶盖20和一底座21保持折叠状态。该顶盖还用来封闭由侧壁8、9和后壁10界定的制冷室的顶端。该制冷室中有一底板16封闭该制冷室的底端。底座21用连接件22安装制冷系统的各部件，特别是压缩机、控制系统和膨胀阀。底座21也可开口。对于包括一食物保鲜的冷藏室和一冷冻室的冰箱而言，可设置一隔板17。
在图7所示另一实施例中，底板与底座制成一体而成为一底件50。底件50下部形成了一个以侧部基脚52为界的空间。一承重盘53可滑动地装配在底件50下方的空间内并受侧部基脚52的支撑，制冷系统的机械部件装在该承重盘的连接件54上。
下面结合图1-4说明侧壁和后壁8、9、10的制造方法以及冰箱的总装。
如图5和7所示，冰箱的顶盖20封闭冰箱的顶端的同时还使壁8-10的顶边25固定在顶盖底面上的凹槽中。壁8-10的顶边25最好有一削减部26，从而形成一舌状凸起，从而凸起插入凹槽中后，顶盖20端面27的外侧面与侧壁和后壁8-10的外表面齐平。
同样，底座21的侧边处有凹槽28和29。侧壁8和9的底边的舌状凸起部30插入在凹槽28和29中。同样，舌状凸起或削减部使得底座的侧面与冰箱箱体的侧面齐平。如图5以及图3所示，箱体的后壁最好终止于侧壁8和9的底边的上方。从而冰箱后面留出一开口用来安装制冷系统的各部件(在图5中装在底座连接件22上，在图7中装在支撑盘51上)并保持所需通风。底座21最好还包括稍稍向下伸展的脚部33，从而把冰箱箱体支撑在一支撑面上。必要时，也可安装公知的可调节脚。
如图5所示，底板16的侧边31、32插入在冰箱箱体内侧面上的凹槽13、15中，其后边34插入在后壁底边上的凹槽14中。该底板最好包括一从一水平前部35经一倾斜弧形过渡区37到一水平后部36的过渡。该底板上可有滴水盘38之类的细部。
如图6和7所示，该底件的另一实施例在一前平台55与一后平台56之间也有一同样的过渡。该冰箱箱体侧壁的内表面有一曲线缺口57、58，其顶边的形状与所述底件的横向顶边相同，所述底座的竖立部位于该缺口57、58中。
如图5和7所示，箱体的侧壁8、9和后壁10的内表面上制有细部，例如与内表面制成一体的托盘支撑导轨39。这些壁上的这类细部的其它制作方式对本领域的技术人员是显然的，例如把挑口板(facia panel)塑料焊接在这些平面上，但这种细部制作方法效率低下。
同样，隔板17可包含门铰链、通风管道和内部装饰。
如图1和3所示，通过用厚度、颜色或材料成分可以不同的两塑料片材2、3把箱体的内部和外部同时热成形，箱体的侧壁8、9和后壁10被制成一个单一的平板1。片材2、3加热而且起初其周边用支撑凸缘12固定。当把内模4和外模5包住片材2、3后把空气注入片材2、3之间，以便进行热成形。双片材热成形工艺是公知的，不再赘述。
所制成的板1有由内模4轮廓中凸脊7形成的两个折叠/铰接区6。这些铰接区6把该板划分成三个空腔，两个为侧壁8、9，一个为后壁10。在铰接区中内片材4与外片材5相接而形成折叠线。
如图4所示，热成形后板留在模具中，用热成形工艺把绝热泡沫塑料从注入孔11注入这三个空腔中。热成形模具4、5然后用作起泡夹具，在泡沫塑料膨胀、定形的同时支撑各壁。
泡沫塑料固化足够时间后，从模具4、5和支撑凸缘12中取出其中有泡沫塑料的板。如图4所示，在从模具中取出过程中或取出后隔一段时间后在装配前修剪掉模制件1上的过多材料40。该材料最好修剪成与内外片材之间的接头41齐平，使得外表平整。露出的接头可抛光，以美化外观。
图8示出热成形板转角区的优选结构。该转角区在冰箱的一侧壁8与后壁10之间，双片材可为内片材或外片材，决定于它们是形成该转角的内表面还是外表面。折叠时该板在接缝6处转过一定位角，从而内片材与外片材接触，该定位角与装配后两壁之间的角对应。为此，靠近接缝的内片材的区域64、68包括一与定位角相等的角，从而当该板在接缝处折叠时，这两个区域相接，其间不留下很大缝隙。在极端情况下，这一夹角当然可偏向这一或那一片材，使得接缝的宽度与该板的厚度大致相等。但在优选实施例中，为提高强度和便于制作，该对表面64、68与该片材平面各成45°角，从而它们之间的夹角为约90°。
外片材在该热成形板的接缝处、在构成后壁的板段10的外表面61与构成侧壁的板段10的次外表面62之间有一过渡，该过渡与该板在接缝6处折叠时转过的定位角互补。因此，当外片材折叠时转过该定位角时，接缝两边的表面61与次表面62齐平而成为连续平面即后壁平面。外片材在构成侧壁的板的一部分中当然还有一过渡，该过渡在该板段的次表面62与主表面63之间，折叠后，该过渡构成箱体的转角。因此，箱体的侧板与后板的接缝线与转角平行而不是在转角上，从而隐藏在冰箱背后，从正面几乎看不到任何装配痕迹。图9示出该板处于折叠状态。接缝6显然在冰箱箱体的后面上。只要不背离本发明的这一方面，这些过渡也可呈其它形状，这决定于板折叠时转过的角度、板段的总弧度和转角本身的弧度。
下面结合图8和9说明优选折叠过程。在接缝处折叠双片材板的现有技术建议，在刚要折叠前把例如高电阻金属丝之类的热辐射加热器靠近接缝，从而进行加热以软化接缝。但是，对于其大小必须足以形成冰箱箱体各壁的板来说，我们发现，比方说由于金属丝下垂以及在靠近接缝以便加热接缝时会同时加热周围片材而使其变形，因此这类方法不足取。因此，在本优选组装方法中，所用加热器为一支撑在一加热器支撑件72上的传热率很高的加热头74，它可相对该板移动，从而其加热面77与该板的接缝6发生接触。加热头和加热面最好与接缝6共同延展。为加大接缝区的接触面从而加大受热面，可比方说在接缝的内表面上用倒角69来增加其宽度。这一加热过程可在板仍支撑在其下模上时进行，但是，只要与加热头74和加热头支撑件72的相对位置十分精确，该板也可支撑在另一支撑面上。不难看出，使用传热加热头时加热更集中，特别当传热头更容易用铝块之类的坚固、刚性材料制成时。这不会对该片材的周围区域加热，而且加热时间缩短。传热头上最好有便于传热头与被加热塑料脱离、不造成塑料变形的涂层。为此，使用PTFE(特氟隆)涂层是较适合的。
如上所述，板的内片材在表面68与64之间有一角度，表面68与64在已装配的结构中相接。至少在分别与表面68和64邻近、但离接缝6更远的表面65和76区域之间也有一相同的角。由于该步骤最好包含在外片材中(理由如上所述)，这些表面65和76区域也互相对齐和靠近。在本发明该优选实施例中，表面68与64和/或65与76接靠时还使两板段在与接缝6相间距部位处熔合在一起，从而使两板段永远锁定在其折叠位置上。为便于熔合，表面76、65上有凸起的塑料球结节66、67。球结节可为局部凸起，也可为与接缝6平行的凸脊。传热头74还包括加热面71和73，支撑件72使得这些加热面在接触面77抵靠接缝6的同时分别与球结节66和67接触。当球结节熔化后折叠该板时，球结节互相接触、熔合在一起，在该板的内片材的表面65与76之间形成一焊点75。使用中，该焊点不仅大大提高箱体的刚性，还在内片材的表面68与64之间的缝隙表面处密封该缝隙。
所示转角在冰箱箱体的左侧壁8与后壁10之间，但它显然适用于一热成形板的板段之间的其它缝隙，该板用来折叠成箱体之类一物件，特别是，该箱体的外表面之一在使用时看不到。
在图5实施例中，底板16在折叠前引入该组件中，然后在侧壁8、9完全折叠后用该板的侧壁和后壁中的凹槽13、14和15锁定。底板16最好为一夹在一塑料外皮中的泡沫塑料芯。
在图5和7所示双温冰箱中，结构与底板16相似的一隔板17插入在两侧壁的槽道18、19中或横穿过板(见图3)的凹槽20以形成冷藏室与冷冻室之间的分隔。该隔板17互锁折叠板1的侧壁8、9，转而由该折叠板的约束边锁定。该隔板包含门铰链、通风管道和内部装饰这些细部。该隔板可用燕尾槽、榫槽、榫头与所述侧壁连接，也可只使用长方形侧边。
装好该隔板和/或底板后，把顶盖20装到该折叠板的顶边上。由削减部26形成的舌状凸起插入顶盖20底面上的凹槽中，从而保持折叠状态。
然后在折叠板的底边上装上底座21，侧边8和9底边上的舌状凸起插入底座两边顶面上的凹槽28、29中。如图5和7所示，与顶盖20一样，底座21使由壁形成的板1保持折叠状态。
图7示出把制冷系统装入该冰箱中的某些细部。特别是，该冰箱在冷藏室和冷冻室中各有一导流板80、81，每一导流板形成其室的后壁。可部分(例如槽道82)地形成在该双片材热成形板中的空气循环管道隐藏在这些导流板后面。冷冻室的导流板位于与热成形板的内表面相间隔的前方，其边固定在该室侧壁的凹槽83中，从而其后方形成一个次室。该次室用来放置制冷系统的蒸发器。通风管道中有一个或多个风扇使得空气在蒸发器外表面上流通，冷却空气然后从导流板80、81中的孔85、86按需要流入冷冻室或冷藏室中。热成形板上可有一槽道84以供不时地形成在蒸发器上的冷凝水流出后在除霜过程中除去。槽道84通向压缩机紧上方的一位置，从而冷凝水落在一装在压缩机头部上的接水盘中，从而吸收压缩机上的热量后蒸发掉。这种结构的制冷系统是公知的，并不构成本发明的重要部分。
可把标准蒸汽压缩制冷系统之类的一制冷系统装在该箱体中。在这种系统中，压缩机、冷凝器和控制系统可装在底座上，蒸发器比方说可以结合图6和7所述方式装在制冷空间中。门装在冰箱正面，支撑在顶盖和底座前边上和两室隔板上的铰链部件之间。与现有技术中一样，门最好也用双片材热成形制成，其空腔中注入绝热泡沫塑料。
以上结合冰箱箱体进行了说明。该过程也可用于其它种种不同箱体，特别是双壁绝热结构箱体。还可看出，尽管上述箱体为一对侧壁和一后壁，但可简单改变成包括任何数量的壁，各壁之间的接靠过渡面之间的夹角相应改变。
不难看出，上述本发明冰箱箱体较之现有技术具有很大优点。该冰箱箱体结构简单，部件少，这些部件装在一起时自动互锁，从而箱体的强度和刚性提高。与顶盖与折叠壁组件的顶边的啮合一样，隔板和底板也与箱体互锁在一起，因此隔热和隔湿性能好。其上有制冷系统的许多机械部件的底座位于底板底下，这些部件容易从冰箱后面装入，箱体中的制冷空间增大。还可看出，顶盖和折叠板的外片材的外部形状可模制成光滑弧形。
还可看出，由于组件的简单性，本发明冰箱箱体可以平面状运输，然后在与部件制造地点不同的另一地点进行最后组装。这使得运输成本大大下降，因为低密度产品(例如冰箱)是根据体积而非重量计算运费的。

Claims (43)

1、一种冰箱箱体，包括：
一由双壁绝热塑料件，其由多个细长接缝划分为三个或三个以上壁段，这些壁段顺序地并排布置，在这些接缝处所述双壁接触，所述双壁绝热塑料件在所述接缝处折叠，从而所述壁段顺序地形成一箱体的三个或三个以上的侧壁，这些侧壁在所述细长接缝处连接，所述各侧壁之间界定了一制冷空间，
一与所述壁件的顶边连接、使得所述壁件保持所述折叠形状的顶盖，所述顶盖封闭所述制冷空间的顶端，
一与所述壁件底边连接、使得所述壁件保持所述折叠形状的底座，所述底座直接或间接地支撑所述制冷系统的机械部件，以及
与所述底座制成一体或分开制造的底件，用来封闭所述制冷室的底端。
2、按权利要求1所述的冰箱箱体，其特征在于，所述顶盖有一外表面和一内表面，该内表面上沿其至少两边或靠近其周边有一凹槽，所述折叠塑料壁件的顶边装配到所述顶盖凹槽中，所述顶盖凹槽使得所述壁件的顶边保持所述折叠状态。
3、按权利要求2所述的冰箱箱体，其特征在于，所述壁件的所述顶边和底边的插入所述顶盖和/或底座的所述凹槽中的部分构作成一突舌，所述突舌的厚度小于所述壁件的总厚度，该突舌插入在该凹槽中，使得顶盖和底座的外侧面和后面与由折叠塑料壁件构成的箱体侧面齐平。
4、按权利要求1-3中任一权利要求所述的冰箱箱体，其特征在于，所述双壁绝热塑料件一般构作成包括一面向内的塑料片材和一面向外塑料片材，所述面向内的塑料片材的侧壁和/或后壁部上制有如盘支撑或类似物的内部细部，所述内壁与所述外壁用一绝热材料隔开，但在所述接缝处或沿所述接缝接触所述外壁，所述内壁在每一所述接缝每一边各有一过渡面，该过渡面伸展在所述接缝与所述内壁的构成箱体内壁的主要部分之间，两边的所述过渡面抵靠所述折叠壁件。
5、按权利要求4所述的冰箱箱体，其特征在于，所述双壁绝热塑料件划分成三个壁段，折叠后相继形成左侧壁、后壁和右侧壁，所述塑料件的所述内壁的所述两过渡面之间形成一约90°的夹角。
6、按权利要求4或5所述的冰箱箱体，其特征在于，接缝两边的所述两过渡面中的至少一个过渡面包括一纵向凹槽，所述两过渡面抵靠折叠的所述壁件时围成一垂直轴，所述轴中可封装制冷系统元件和/或辅助元件和/或包括把抵靠过渡面锁定在所述抵靠状态的装置，所述轴中也可什么都不装。
7、按权利要求1-6中任一权利要求所述的冰箱箱体，其特征在于，所述双壁绝热塑料件划分成三块板，相继形成所述冰箱的左侧壁、后壁和右侧壁，所述壁件的所述后壁板最好比所述壁件的所述左侧壁板和右侧壁板短，从而所述壁件的底边中形成一凹口，所述凹口伸展在所述细长接缝之间，所述凹口最好在所述冰箱后部靠近所述底座附近形成一开口空间，所述底座沿其相对两边包括所述壁夹持凹槽，所述凹槽夹持所述左侧壁和右侧壁的底边，从而与所述壁件连接并使得所述壁件保持所述折叠状态。
8、一种按权利要求1-7中任一权利要求所述的双温冰箱的冰箱箱体，其特征在于，所述箱体包括一把所述箱体隔成一冷藏室和一冷冻室的隔板，所述隔板的两边插入所述箱体的所述左侧壁和右侧壁的至少内表面中的凹槽中。
9、按权利要求1-8中任一权利要求所述的冰箱箱体，其特征在于，包括一与所述底座分开的底件，所述底件包括一横跨在所述折叠塑料件的三个或三个以上侧边之间的一底板，在这些侧壁界定的空间中，所述隔板单独或与所述底座一起封闭所述制冷空间的底端。
10、按权利要求9所述的冰箱箱体，其特征在于，所述底座在其顶面上沿其至少两侧边或靠近其周边有一凹槽，所述折叠塑料壁件的底边装配在所述底座凹槽中，所述凹槽使得所述壁件的底边保持所述折叠状态。
11、按权利要求9或10所述的冰箱箱体，其特征在于，所述底板与所述底座独立，装配在所述折叠塑料件的左侧壁和右侧壁的内表面的相配凹槽中，所述底板的后边比前边高。
12、按权利要求9-11中任一权利要求所述的冰箱箱体，其特征在于，所述底板包括一水平后部、一水平前部和其间的一过渡部，所述左侧壁和右侧壁有供所述底板的左边和右边插入的凹槽，所述凹槽的轮廓与所述底板相同。
13、按权利要求9-12中任一权利要求所述的冰箱箱体，其特征在于，所述后壁的底边的内表面包括一供所述底板的后边插入的缺口。
14、按权利要求1-8中任一权利要求所述的冰箱箱体，其特征在于，底件与底座制成一体，所述底座包括一向上底板件，该底板件横跨在所述折叠塑料件的三个或三个以上侧面之间，封闭所述制冷空间的底端，所述底板件下方在所述底座的向下伸展的冰箱支撑件之间有一空间，所述空间中可装入所述冰箱的机械和/或电部件。
15、按权利要求14所述的冰箱箱体，其特征在于，所述向下伸展冰箱支撑件包括与所述箱体的至少左侧和右侧的底边连接的装置。
16、按权利要求14或15所述的冰箱箱体，其特征在于，所述向下伸展冰箱支撑件各包括一侧向伸展件，该侧向伸展件有一向上凹槽，所述箱体的左侧壁或右侧壁的底边可装配在该凹槽中。
17、按权利要求14-16中任一权利要求所述的冰箱箱体，其特征在于，所述底座包括一可拆卸盘，该盘上可放置所述冰箱机械部件，所述盘被所述向下伸展件支撑在所述底件下方。
18、按权利要求1-8中任一权利要求所述的冰箱箱体，其特征在于，其上放置冰箱机械部件的一盘在所述底件下方与所述底座制成一体。
19、按权利要求14-17中任一权利要求所述的冰箱箱体，其特征在于，所述底板的至少顶面包括一后平台、一前平台和其间的一过渡部，冰箱的所述左侧壁和右侧壁的内表面在其底边处包括缺口，所述底板件的侧边可插入缺口中。
20、一冰箱，包括按权利要求1-19中任一权利要求所述的冰箱箱体；装在所述冰箱箱体上、封闭所述制冷空间的正面、从而封闭整个所述制冷空间的一门和一使所述制冷空间制冷的制冷系统，所述制冷系统的至少一部分装在所述底座上。
21、一种冰箱箱体的制造方法，包括下列步骤：
(a)热成形一双壁绝热塑料件，其由多个细长接缝划分成三个或三个以上壁段，在这些接缝处所述双壁顺序地并排布置，
(b)沿所述各接缝折叠所述塑料壁件，形成一箱体的三个或三个以上的侧壁，这些侧壁在所述各细长接缝处连接，所述各侧壁之间界定了一制冷空间，以及
(c)把一顶盖装在所述箱体上，使得所述壁件保持所述折叠形状并封闭所述制冷空间的顶端，以及
(d)把一底座装在所述壁件的底边上，使得所述壁件的底边保持所述折叠形状。
22、按权利要求21所述的冰箱箱体制造方法，其特征在于，在步骤(b)之前包括下列步骤：
(i)当所述塑料件仍在其热成形模具中时，把发泡材料注入所述各壁段的空腔中，所述发泡材料膨胀成泡沫填满所述空腔后固化，以及
(ii)然后从热成形模具中取出所述塑料件。
23、按权利要求21或22所述的冰箱箱体制造方法，其特征在于，包括如下步骤：在折叠所述塑料壁件前，除去内半模，所述壁件仍支撑在所述热成形模具的外半模上，此时加热所述壁件的所述接缝区而使所述接缝处的材料在折叠前软化。
24、按权利要求23所述的冰箱箱体制造方法，其特征在于，在除去所述内半模后、在所述折叠前包括下列步骤：在所述壁件内表面上的槽道中铺设配电线和/或制冷机械部件。
25、按权利要求21-24中任一权利要求所述的冰箱箱体制造方法，其特征在于，所述壁件至少在左侧壁部和右侧壁部的靠近其底边处有凹槽，所述方法包括：把所述壁件折叠成所述箱体时，夹持一底板，使得所述底板的左边和右边夹持在所述壁件的侧壁部的所述凹槽中。
26、按权利要求21-25中任一权利要求所述的冰箱箱体制造方法，其特征在于，包括把一隔板插入所述壁件的所述左侧壁部和右侧壁部上、所述顶盖与所述底板之间的一部位处的凹槽中，从而形成一冷藏室/冷冻室隔板。
27、一种箱体，包括：
一双壁绝热塑料件，其由多个细长接缝划分成三个或三个以上壁段，这些壁段顺序地并排布置，在这些接缝处所述双壁接触，所述双壁绝热塑料件在所述接缝处折叠，从而所述壁段顺序地形成一箱体的三个或三个以上的侧壁，这些侧壁在所述细长接缝处连接，以及
一顶盖和/或底盖，它有一内表面和一外表面，其内表面上沿其至少两边或靠近其周边有一凹槽，所述折叠的塑料壁件的顶边和/或底边插入所述凹槽中，所述凹槽使得所述壁件保持所述折叠形状。
28、按权利要求27所述的箱体，其特征在于，一个或多个接缝不与所述箱体的侧面之间的转角重合，这些侧面与由所述折叠接缝连接的所述壁段对应。
29、按权利要求27所述的箱体，其特征在于，所述双壁塑料件有一面向内片材和一面向外片材，所述壁件在靠近至少一个所述接缝处制成使得所述面向内片材接触自身，该面向内片材的在所述接缝两边、与所述接缝相间距的两部分互相接触，所述两接触部熔合在一起。
30、一用具的箱体，包括一用双片材热成形制成的壁件，所述壁件包括多张板，所述多张板由一个或多个接合边互相连接，其中，所述双片材接触而形成一接缝，在所述用具中所述壁件沿一个或多个所述接缝折叠，从而所述多张板形成所述用具的多个壁，该用具的整体构型与所述壁件在起初热成形时的结构不同，其中所述折叠接缝中的一个或多个接缝不与所述用具的壁之间的转角重合，这些壁与由折叠接缝连接的板对应。
31、按权利要求30所述的箱体，其特征在于，所述折叠接缝在一板的至少构成所述一板的所述转角的一所述壁的表面的一边与另一板的构成一表面的一边之间，该表面与上述板的至少构成所述转角的上述壁的该表面成一角度，所述壁件在所述接缝处折叠时转过所述角度，从而与上述板成一角度的所述表面构成所述转角的所述一个所述壁并把所述折叠接缝与所述转角隔开。
32、一用具的箱体，包括一用双片材热成形制成的壁件，所述壁件包括多张板，所述多张板由一个或多个接合边互相连接，其中，所述双片材接触而形成一接缝，在所述用具中所述壁件沿一个或多个所述接缝折叠，从而所述多张板形成所述用具的多个壁，该用具的整体构型与所述壁件在起初热成形时的结构不同，在至少一个所述接缝处，所述双壁塑料件有一面向内片材和一面向外片材，在所述接缝旁这样形成所述壁件，即在所述折叠状态下所述面向内片材接触本身，该面向内片材在所述接缝两边、与所述接缝相间距的两部分互相接触，所述两接触部互相熔合在一起。
33、按权利要求32所述的箱体，其特征在于，所述内片材的所述两部分沿一与所述接缝平行伸展的直线互相接触。
34、一用双片材热成形制成的壁件，包括一个或多个接缝，所述双片材在接缝处接触，所述壁件可在一个或多个所述接缝处折叠而形成多个壁，其特征在于，至少一个所述接缝在折叠时转过一定位角；所述双片材中的至少一个所述片材在所述接缝处或大致在所述接缝处在该片材的两表面之间有一过渡，该过渡与所述定位角互补，从而当所述接缝在折叠时转过所述定位角时，所述两表面穿过所述接缝而连续。
35、按权利要求34所述的壁件，其特征在于，所述两表面之一有与所述接缝平行、但与该接缝相间距的另一过渡，转过该定位角后，与所述接缝相间距的所述另一个过渡后方的所述表面与所述第一过渡前方的所述表面共平面。
36、按权利要求35所述的壁件，其特征在于，包括一对所述接缝，这两接缝平行并相间距，所述壁件划分成三块并排的板，所述壁件的一片材的每一板有一主平面，这三个主平面互相平行，该对接缝位于所述中间板的主平面的两边，两块外部板各有一垂直伸展的次平面，每一次平面从其板的主平面的朝向接缝的一边伸展到该接缝，所述定位角约为90°，从而当所述接缝折叠而转过所述定位角时，所述外部板的所述次平面与所述中间板的所述主平面共平面，所述两外部板从所述中间板的边垂直伸展，折叠接缝整个位于所述中间板的外表面上。
37、制备一双片材热成形壁件的设备，该壁件包括一个或多个接缝，所述壁件在这些接缝处折叠时所述壁件在所述接缝处的两内表面抵靠在一起，该设备包括：一传热头，该传热头有一沿所述待折叠接缝接触该接缝的加热面；加热所述传热头的装置，所述传热头支撑在一支撑装置上，该支撑装置与所述壁件的一支撑装置一起，使所述加热面与所述接缝接触，从而把热量从所述传热头传到所述接缝上，从而软化所述接缝，以便折叠。
38、按权利要求37所述的设备，其特征在于，所述加热头包括另一个或多个加热面，在用来加热所述接缝的加热面接触所述接缝时用来接触所述壁件的所述两内表面上的一些点或一些路径，从而可用所述另一个或多个加热面传热而集中软化或熔化所述点或路径处的塑料，从而，如所述两表面在进行所述折叠后立即接靠，这些点或路径在接靠在一起的该两表面之间形成粘合点。
39、一种结合图1-5所述和所示的冰箱箱体。
40、一种结合各附图所述和所示的冰箱箱体制造方法。
41、一种用具的一箱体，其特征在于，包括结合图9所述和所示的转角结构。
42、一种结合图6和7所述和所示的冰箱箱体。
43、按权利要求21-26中任一权利要求所述的方法制造的冰箱箱体。
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