EP2473803A2

EP2473803A2 - High - strength refrigerator door

Info

Publication number: EP2473803A2
Application number: EP10747223A
Authority: EP
Inventors: Soner Kahraman; Ahmet Onur Moza; Mert Tosun; Fatih Mehmet Ozturk
Original assignee: Arcelik AS
Current assignee: Arcelik AS
Priority date: 2009-09-01
Filing date: 2010-08-31
Publication date: 2012-07-11
Also published as: CN102483289A; CN102483289B; WO2011026817A2; WO2011026817A3

Abstract

The present invention relates to a refrigerator door (1) comprising a door plate (2) which is formed by bending the edges of a rectangular sheet, an upper (3) and a lower cap (103) which are closed onto the upper end and the lower end of the door plate (2) before the polyurethane injection process and a support plate (7) which provides the support of the cap (3, 103) at the upper and lower ends of the door plate (2) by extending perpendicular to the cap (3, 103) plane and through the portion wherein the rear bent portions (6) are disposed and wherein the side walls (5) to which the rear bent portions (6) are connected are prevented from being deformed after the polyurethane injection process by holding the rear bent portions (6) by means of two holding extensions (8) which are integrated onto the said support plate (7) and wherein a gap (G) into which the rear bent portions (6) on the rear wall side of the door plate (2) are placed and the locking detents (9) are disposed between the support plate (7) and the holding extensions (8).

Description

HIGH - STRENGTH REFRIGERATOR DOOR

[0001] The present invention relates to a refrigerator door into the inner volume of which polyurethane is injected during its production and which is prevented from being deformed.

[0002] The refrigerator doors generally consist of a front sheet which forms the front surface thereof and which is produced from steel sheet material, side walls which are produced by bending the edges of the front sheet, a rear wall which is disposed at the inner volume of the refrigerator and produced from plastic material and caps which are closed onto the upper and lower portions thereof. In the production of refrigerator doors, polyurethane is injected into the closed volume surrounded by the front sheet, side walls, the rear wall and the upper and lower caps and polyurethane insulation material injected into the inner volume of the door inflates and exerts pressure against all the surfaces which surround polyurethane insulation material from inside. Due to the pressure exerted by the polyurethane, polyurethane leakages may occur at the regions where the lower and upper caps are mounted and side walls open towards the outside and thus are deformed. For this reason, the refrigerator door cannot maintain the desired form after the polyurethane injection process and this causes production losses. In the state of the art, side holding extensions (8') which extend towards the outside of the side wall (5') through the cap (3') seated on the refrigerator door (1 ') cannot provide the sufficient strength to prevent the side walls (5') from expanding to right and left after the polyurethane injection process (Figure 1). The side holding extensions (8') on the said cap (3') form undesired projections over the side wall (5') and these undesired projections prevent trim-kit (glass-covering) process on the refrigerator door (1 ').

[0003] In the state of the art Japanese Patent Application No. JP2008304075, a refrigerator the door of which is prevented from being deformed after the production is described. The refrigerator door is formed by combining a front plate, a rear plate, an upper cap and a lower cap and foam insulation material is filled into the closed volume therebetween. Fine pores on the upper and lower caps allow gas outlet during the cooling of the insulation material and thus the insulation material can fill all the gaps in the inner part of the door.

[0004] In the state of the art Patent Application No. JP200097550 a refrigerator door is described which is produced by combining a front plate, a rear plate and upper and lower caps which are closed onto the upper and lower portions and wherein polyurethane foam insulation material is injected into the closed volume therebetween. The side wall of the front plate of the refrigerator door is formed by being bent and a grip portion is formed in the form of a recess, and thus number of elements is decreased.

[0005] The aim of the present invention is the realization of a refrigerator door which is prevented from being deformed after the polyurethane injection process.

[0006] The refrigerator door realized in order to attain the aim of the present

invention is composed of a door plate which forms the main body thereof, the edges of which are shaped by being bent, which is in the form of an involute U when looked from above, a rear wall which is disposed at the back side of the door plate and which faces the inside of the refrigerator and an upper and a lower cap which are seated on the upper and lower ends of the door plate, the side walls of the door plate are prevented from being deformed by extending to right and left due to the pressure generated after the polyurethane injection process by means of the locking detents located on the caps.

[0007] The door plate has a front wall disposed on the front side which faces the user, two side walls which are formed by bending the right and the left edges thereof and two rear bent portions which are formed by bending the rear edges of the side walls inwards.

[0008] The refrigerator door of the present invention comprises a support plate which is produced as a single piece together with the cap and which supports the cap, two holding extensions in L-form which are integrated onto the support plate, which extend to right and left parallel to the support plate and wherein there is a gap therebetween in which the rear bent portions of the door plate are placed and more than one locking detent which extend towards the support plate from the inner surface of the holding extension and which prevent the side wall to which the rear bent portion is connected from expanding towards the outside after the polyurethane injection process by holding the rear bent portion placed into the gap.

[0009] In an embodiment of the present invention, the locking detents are in

inclined trapezoid or sawtooth form at the opposite direction to the opening direction of the side walls and are arranged in series at the horizontal plane in the gap between the holding extension and the support plate.

[0010] In this embodiment, the door plate comprises more than one cut-out

arranged in series at the horizontal plane, which are disposed in the portion of the rear bent portion which is in the gap, which enables the ends of the locking detents to pass through the rear bent portion to be locked.

[001 1] The locking detents in sawtooth or trapezoid form lodge into the cut-outs formed on the rear bent portion and provide the locking of the rear bent portion inside the gap when the rear bent portion of the door plate is placed into the gap.

[0012] In another embodiment of the present invention, the number of the

cut-outs is greater than the number of the locking detents. Thus, measurement deviation problems which may occur during the forming of the cut-outs on the rear bent portion or the assembly of the cap are eliminated and the alignment of each locking detent with a cut-out is provided.

[0013] The door plate furthermore comprises two front edge bent portions which are formed by bending the upper and the lower edges of the front wall of the door plate at least partially inwards to bring them to horizontal position and which provide the fixing of the upper and the lower caps without forming protrusions and four side edge bent portions which are formed by bending the upper and the lower edges of the side walls of the door plate inwards to bring them to horizontal position.

[0014] The cap comprises a front support extension in L-form which is integrated onto the inner part of the front edge of the door plate which seats onto the front wall and which provides the fixing of the cap to the door plate by grasping the front edge bent portion and two side support extensions in L-form which are integrated onto the inner parts of the side edges which seat onto the side walls and which provide the fixing of the cap to the door plate by grasping the side edge bent portion.

[0015] The front support extension and the side support extensions provide the fixing of the caps mounted to the upper and the lower ends of the door plate without forming protrusions on the front wall and the side walls and prevent the caps from detaching from the door plate due to the

polyurethane pressure.

[0016] During the production of the refrigerator door of the present invention, the expanding of the side walls to right and left due to the polyurethane pressure is provided by the locking detents hidden at the rear wall side of the refrigerator door and which has high strength. Furthermore, the upper and the lower caps are fixed to the front wall and the side walls of the door plate without forming protrusions, thus improving esthetic appearance.

[0017] The refrigerator door realized in order to attain the aim of the present

invention is illustrated in the attached figures, where:

[0018] Figure 1 - is the schematic view of a refrigerator door in the state of the art.

[0019] Figure 2 - is the schematic view of the door plate and the upper and the lower caps which form a refrigerator door.

[0020] Figure 3 - is the bottom perspective view of a cap mounted onto the door plate.

[0021] Figure 4 - is the perspective view of detail A in Figure 3.

[0022] Figure 5 - is the perspective view of the upper portion of a door plate.

[0023] Figure 6 - is the perspective view of detail B in Figure 5.

[0024] Figure 7 - is the schematic view of locking detail on a cap.

[0025] Figure 8 - is the schematic view of locking detail on a cap in another

embodiment of the present invention.

[0026] The elements illustrated in the figures are numbered as follows:

1. Refrigerator door

2. Door plate

3. , 103. Cap 4. Front wall

5. Side wall

6. Rear bent portion

7. Support plate

8. Holding extension

9. Locking detent

10. Cut-out

1 1. Front edge bent portion

12. Side edge bent portion

13. Front support extension

14. Side support extension

[0027] The refrigerator door (1 ) comprises a door plate (2) which is formed by bending the edges of a rectangular sheet, a rear wall (not illustrated in the figures) which is disposed at the side facing the storage volume of the refrigerator and which is produced from plastic material and an upper cap (3) and a lower cap (103) which are seated onto the upper end and lower end of the door plate (2) before the polyurethane injection process.

[0028] The door plate (2) has an involute U-shaped cross-section when looked from above and comprises a front wall (4) disposed at the front side facing the user, two side walls (5) which are formed by bending the right and left edges thereof and two rear bent portions (6) which are form by bending the rear edges of the side walls (5) towards each other parallel to the front wall (4) (Figure 2).

[0029] During the production of the refrigerator door (1), the door plate (2) is

combined with the rear wall after being formed by being bent, the upper and the lower ends thereof are closed with the caps (3, 103) and insulation material, for example polyurethane is injected into the closed volume thus formed.

[0030] The cap (3, 103) comprises

[0031] - at least one support plate (7) which extends to the rear edge thereof, which extends vertical to the cap (3, 103) plane towards the inside through the part wherein the rear bent portions (6) are disposed and which supports the cap (3, 103), [0032] - two holding extensions (8) in L-form which are integrated onto the end portions of the support plate (7), which extend to right and left parallel to the support plate (7) and wherein there is a gap (G) between the holding extensions (8) and the support plate (7) in which the rear bent portions (6) are placed and

[0033] - more than one locking detent (9) which extend towards the support plate (7) from the inner surface of the holding extension (8) and which prevent the side wall (5) to which the rear bent portion (6) is connected from expanding outwards after the polyurethane injection process by holding the rear bent portion (6) which is placed into the gap (G) (Figure 3, Figure 4, Figure 7).

[0034] During the production of the refrigerator door (1), the outwards expanding of the side walls (5) are prevented by means of the locking detents (9) after the polyurethane injection process. The locking detents (9) are hidden in the portion of the door plate (2) wherein the rear bent portions (6) combined with the rear wall are disposed and do not form any protrusion or overflow on the surfaces which can be seen by the user. During the grouping of the elements forming the refrigerator door (1 ), the side walls (5) of the door plate (2) in U-form are stretched to left and right while the caps (3, 103) are closed onto the upper and lower ends of the door plate (2) and the rear bent portion (6) is pushed into the gap (G) between the support plate (7) on the cap (3, 103) and the holding extension (8). When the cap (3, 103) is closed onto the door plate (2), rear bent portions (6) are locked in the gap (G) by the locking detents (9). The locking detents (9) prevent the side walls (5) to which the rear bent portions (6) are connected from expanding to right and left after the polyurethane injection process by increasing the strength of the cap (3, 103)-door plate (2) connection.

[0035] In an embodiment of the present invention, the locking detents (9) are in trapezoid or sawtooth form inclined at the opposite direction to the opening direction of the side walls (5) and are arranged in series at the horizontal direction in the gap (G).

[0036] The door plate (2) comprises more than one cut-out (10) arranged in series at the horizontal direction, which are disposed in the portion of the rear bent portion (6) which is in the gap (G), which enables the ends of the locking detents (9) to pass through the rear bent portion (6) to be locked (Figure 5, Figure 6, Figure 7).

[0037] When the rear bent portion (6) is placed into the gap (G), the locking

detents (9) in sawtooth or trapezoid form lodge into the cut-outs (10) on the rear bent portion (6) and provide the rear bent portion (6) to be locked such as not to detach from the gap (G).

[0038] In another embodiment of the present invention, the number of the

cut-outs (10) is greater than the number of the locking detents (9) (Figure 8). Thus, measurement deviation problems which may occur during the forming of the cut-outs (10) on the rear bent portion (6) or the assembly of the cap (3, 103) are eliminated during the production and the alignment of each locking detent (9) with a cut-out (10) while the cap (3, 103) is mounted onto the door plate (2) is provided.

[0039] The door plate (2) furthermore comprises two front edge bent portions (1 1 ) which are formed by bending the upper and the lower edges of the front wall (4) at least partially inwards to bring them to horizontal position and which provide the fixing of the upper and the lower caps (3, 103) without forming protrusions and four side edge bent portions (12) which are formed by bending the upper and the lower edges of the side walls (5) inwards to bring them to horizontal position (Figure 6).

[0040] The cap (3, 103) comprises a front support extension (13) in L-form which is integrated onto the inner part of the front edge thereof which seats onto the front wall (4) and which provides the fixing of the cap (3, 103) to the door plate (2) by grasping the front edge bent portion (1 1 ) and two side support extensions (14) in L-form which are integrated onto the inner parts of the side edges which seat onto the side walls (5) and which provide the fixing of the cap (3, 103) to the door plate (2) by grasping the side edge bent portion (12).

[0041] The front support extension (13) and the side support extensions (14) provide the fixing of the caps (3, 103) mounted to the upper and the lower ends of the door plate (2) without forming protrusions on the front wall (4) and the side walls (5) and prevent the caps (3, 103) from detaching from the door plate (2) due to the polyurethane pressure.

[0042] During the production of the refrigerator door (1) of the present invention, the expanding of the side walls (5) to right and left due to the polyurethane pressure is provided by the locking detents (9) hidden at the rear wall side of the refrigerator door (1 ) and which has high strength. Furthermore, the upper and the lower caps (3, 103) are fixed to the front wall (4) and the side walls (5) of the door plate (2) without forming protrusions, thus improving esthetic appearance and embodiments such as trim-fit onto the refrigerator door (1 ) can be realized without any problems.

[0043] It is to be understood that the present invention is not limited by the

embodiments disclosed above and a person skilled in the art can easily introduce different embodiments. These should be considered within the scope of the protection postulated by the claims of the present invention.

Claims

1. A refrigerator door (1 ) comprising a door plate (2) having a front wall (4) on the front side facing the user which is formed by bending the edges of a

rectangular sheet, the cross-section of which is in involute U-form, two side walls (5) which are formed by bending the right and left edges thereof backwards and two rear bent portions (6) which are formed by bending the rear edges of the side walls (5) towards each other parallel to the front wall (4) and an upper cap (3) and a lower cap (103) which are seated onto the upper end and the lower end of the door plate (2) before the polyurethane injection process,

and characterized in that the cap (3, 103) comprising

- at least one support plate (7) which extends to the rear edge thereof, which extends vertical to the cap (3, 103) plane towards the inside through the part wherein the rear bent portions (6) are disposed and which supports the cap (3, 103),

- two holding extensions (8) in L-form which are integrated onto the end portions of the support plate (7), which extend to right and left paralel to the support plate (7) and wherein there is a gap (G) between the holding extensions (8) and the support plate (7) in which the rear bent portions (6) are placed and

- more than one locking detent (9) which extend towards the support plate (7) from the inner surface of the holding extension (8) and which prevent the side wall (5) to which the rear bent portion (6) is connected from expanding outwards after the polyurethane injection process by holding the rear bent portion (6) which is placed into the gap (G).

2. A refrigerator door (1 ) as in Claim 1 , characterized in that the cap (3, 103) comprising the locking detents (9) which are arranged in series at the horizontal direction in the gap (G) and which are in trapezoid or sawtooth form inclined at the opposite direction to the opening direction of the side walls (5).

3. A refrigerator door (1 ) as in Claim 1 or 2, characterized in that the door plate (2) comprising more than one cut-out (10) arranged in series at the horizontal direction, which are disposed in the portion of the rear bent portion (6) which is in the gap (G), which enables the ends of the locking detents (9) to pass through the rear bent portion (6) to be locked.

4. A refrigerator door (1 ) as in any one of the claims above, characterized in that the door plate (2) comprising more cut-outs (10) than the locking detents (9).

5. A refrigerator door (1 ) as in any one of the claims above, characterized in that the door plate (2) comprising two front edge bent portions (1 1 ) which are formed by bending the upper and the lower edges of the front wall (4) at least partially inwards to bring them to horizontal position and which provide the fixing of the upper and the lower caps (3, 103) without forming protrusions and four side edge bent portions (12) which are formed by bending the upper and the lower edges of the side walls (5) inwards to bring them to horizontal position.

6. A refrigerator door (1 ) as in Claim 5, characterized in that the cap (3, 103) comprising a front support extension (13) in L-form which is integrated onto the inner part of the front edge thereof which seats onto the front wall (4) and which provides the fixing of the cap (3, 103) to the door plate (2) by grasping the front edge bent portion (1 1 ) and two side support extensions (14) in L-form which are integrated onto the inner parts of the side edges which seat onto the side walls (5) and which provide the fixing of the cap (3, 103) to the door plate (2) by grasping the side edge bent portion (12).

7. A refrigerator characterized in that a refrigerator door (1) as in any one of the above claims.