JP2004020149A

JP2004020149A - Manufacturing method for thermal insulation box and refrigerator

Info

Publication number: JP2004020149A
Application number: JP2002179596A
Authority: JP
Inventors: Kazuya Higami; 樋上　和也; Hiroshi Aoki; 青木　宏; Koji Ono; 小野　晃司; Ichiro Tsuji; 辻　一郎; Koichi Kubota; 久保田　孝一
Original assignee: Matsushita Refrigeration Co
Current assignee: Panasonic Holdings Corp
Priority date: 2002-06-20
Filing date: 2002-06-20
Publication date: 2004-01-22
Anticipated expiration: 2022-06-20
Also published as: JP3833971B2

Abstract

<P>PROBLEM TO BE SOLVED: To provide a manufacturing method for a thermal insulation box for a refrigerator having high reliability and saving a working space for a manufacturing process and to provide the refrigerator having vacuum thermal insulation materials. <P>SOLUTION: This thermal insulation box is provided with hard urethane foam and the vacuum thermal insulation materials 15, 16, and 17 between an outer box and an inner box. The sides 13 and the top surface 14 of the outer box are constituted by folding a single outer plate 10 and the vacuum thermal insulation materials 15, 16 and 17 are formed by being stuck to the outer plate 10 after folding the outer plate 10. This constitution can miniaturize the sticking work space and improve the installation efficiency of the working space for the manufacturing process. This constitution can dispense with a problem of exfoliation of the vacuum insulation materials by the impact in the folding. <P>COPYRIGHT: (C)2004,JPO

Description

【０００１】
【発明の属する技術分野】
本発明は、真空断熱材を利用した冷蔵庫の断熱箱体の製造方法に関するものである。
【０００２】
【従来の技術】
近年、冷蔵庫の省エネルギー化や省スペース化を狙いに、冷蔵庫の断熱性能を高める一手段として、高断熱性能を有する真空断熱材を利用する方法があり、省エネルギーの要請が益々高まる今日では、硬質ウレタンフォームと比較して数倍から１０倍程度の断熱性能を有する真空断熱材を適切な範囲内で最大限に利用することにより断熱性能を向上させていくことが急務であるといえる。真空断熱材を利用した高い断熱性能を有する冷蔵庫の断熱箱体の製造方法としては、特開平７−９８０９０号公報などが知られている。
【０００３】
図１５は従来の冷蔵庫の断熱箱体の外箱を折り曲げる前の状態を示す斜視図、図１６は同冷蔵庫の断熱箱体の外箱に真空断熱材を貼り付けた状態を示す斜視図、図１７は同冷蔵庫の断熱箱体の外箱を折り曲げた後の状態を示す斜視図、図１８は同冷蔵庫の断熱箱体の折り曲げ工程を示す工程図である。
【０００４】
以下、図面を参照しながら、上記従来の冷蔵庫の断熱箱体の製造方法について説明する。
【０００５】
１は、鋼板からなる平板で、平板１の長手方向の端部にフランジ２を形成し、折り曲げ部にあらかじめＶカット３を施している（Ｓ１）。その後、真空断熱材４、５、６を平板１に貼り付ける（Ｓ２）。そして、冶具を用いて、Ｖカット３を折り曲げ部として折り曲げ、冷蔵庫の断熱箱体の側面および天面を構成するものである（Ｓ３）。その後、内箱、背板、底板を組み込み、内部に硬質ウレタンフォームを充填、発泡し真空断熱材を適用し、断熱性能の高い冷蔵庫の断熱箱体を製造する。
【０００６】
【発明が解決しようとする課題】
しかしながら、上記従来例に記載されている冷蔵庫の製造方法では、真空断熱材４，５，６を平板１に貼り付けた後に折り曲げるので、折り曲げ時の衝撃により真空断熱材４，５，６、が剥がれる場合が生じる。また、真空断熱材４、５、６を平板１に貼り付ける場合、比較的長い作業時間がかかるために、真空断熱材４、５、６を平板１に貼り付ける作業スペースを大きくしなければならず、製造工程の作業空間の設置効率が低下するという課題を有していた。
【０００７】
本発明は、上記課題に鑑み、信頼性が高く、製造工程の作業空間の省スペース化を図る冷蔵庫の断熱箱体の製造方法および冷蔵庫を提供するものである。
【０００８】
【課題を解決するための手段】
本発明の請求項１に記載の発明は、外箱と内箱の間に硬質ウレタンフォームと真空断熱材とを備えた断熱箱体の製造において、一枚の平板を折り曲げて前記外箱の側面および天面を構成する折り曲げ工程と、前記折り曲げ工程後に外冶具と内冶具を用いて内側と外側からの２平面で挟み込み、真空断熱材を前記外箱の内面に貼り付ける真空断熱材貼り付け工程と、前記外箱に前記内箱を係合して形成された前記真空断熱材を有する空間内に前記硬質ウレタンフォームを充填，発泡させる工程とよりなるものである。
【０００９】
本発明によれば、平板を折り曲げた後に真空断熱材を外箱に貼り付けることにより、貼り付け作業スペースを小さくでき製造工程の作業空間の設置効率を高めることができる。また、折り曲げ時の衝撃により真空断熱材が剥がれる問題も生じない。また、冶具を用いて真空断熱材を貼り付けることにより、非定常な作業がなくなり真空断熱材の破損を防止できる。また、冶具により真空断熱材の貼り付け位置の位置決めが確実となり、貼り付けバラツキを抑えることができる。また、一度に複数の真空断熱材を複数の面に貼り付け可能となり、製造工程の生産効率を高めることができる。また、外冶具と内冶具は、外箱の貼り付け部を内側と外側からの２平面で挟み込む方式としたものであり、真空断熱材貼り付け時、押さえる圧力を均一化でき、真空断熱材接着面の外箱外観変形を防止できる。
【００１０】
本発明の請求項２に記載の発明は、請求項１に記載の発明において、内冶具は、真空断熱材の端部二辺をＬ型支持部で支持するものである。
【００１１】
本発明によれば、真空断熱材をＬ型支持部で支持することで、冶具への支持が確実になるとともに、冶具への支持作業が容易となり製造工程の生産効率を高めることができる。
【００１２】
本発明の請求項３に記載の発明は、請求項１または請求項２に記載の発明において、内冶具は、真空断熱材支持面が一方向から順次外箱の貼り付け面に圧設するものである。
【００１３】
本発明によれば、真空断熱材と外箱との間に空気層が生じず、真空断熱材接着面の外箱外観変形を防止できる。
【００１４】
本発明の請求項４に記載の発明は、外箱と内箱の間に硬質ウレタンフォームと真空断熱材とを備えた断熱箱体の製造において、一枚の平板を折り曲げて前記外箱の側面および天面を構成する折り曲げ工程と、真空断熱材を外箱に貼り付ける真空断熱材貼り付け工程とよりなり、前記真空断熱材貼り付け工程において、真空断熱材に外箱外表面の変形を防止する介在部材をあらかじめ配設した後に、介在部材側を外箱に貼り付けるものである。
【００１５】
本発明によれば、真空断熱材と外箱との間の介在部材が真空断熱材の表面の凹凸、そり等の外箱変形要因を吸収し、外箱外表面の変形を防止できる。また、介在部材をあらかじめ真空断熱材に配設しておくことで、組立工程での生産効率を高めることができる。
【００１６】
本発明の請求項５に記載の発明は、外箱と内箱の間に硬質ウレタンフォームと真空断熱材とを備えた断熱箱体の製造において、一枚の平板を折り曲げて前記外箱の側面および天面を構成する折り曲げ工程と、真空断熱材を外箱に貼り付ける真空断熱材貼り付け工程とよりなり、前記真空断熱材貼り付け工程において、外箱側に外箱外表面の変形を防止する介在部材をあらかじめ配設した後に、真空断熱材を外箱に貼り付けるものである。
【００１７】
本発明によれば、真空断熱材と外箱との間の介在部材が真空断熱材の表面の凹凸、そり等の外箱変形要因を吸収し、外箱外表面の変形を防止できる。また、介在部材をあらかじめ外箱側に配設しておくことで、組立工程での生産効率を高めることができる。
【００１８】
本発明の請求項６に記載の発明は、請求項４または５に記載の発明において、介在部材は真空断熱材よりも軟らかい軟質部材としたものである。
【００１９】
本発明によれば、真空断熱材の表面の凹凸、そり等の外箱変形要因の吸収を軟質部材が行い、外箱外表面の変形を確実に防止できる。
【００２０】
本発明の請求項７に記載の発明は、請求項４または５に記載の発明において、介在部材は真空断熱材よりも硬い硬質部材としたものである。
【００２１】
本発明によれば、真空断熱材よりも硬い硬質部材を介在部材としたことで、真空断熱材の表面の凹凸、そり等の外箱変形要因が外箱外表面に伝わることを防止でき、外箱外表面の変形を防止できる。
【００２２】
本発明の請求項８に記載の発明は、請求項１から請求項７のいずれか一項に記載の発明において、真空断熱材と外箱との接着部材は、真空断熱材側に付設するものである。
【００２３】
本発明によれば、真空断熱材の表面の凹凸、そり等の外箱変形要因を接着部材の厚みが吸収して外箱外表面の変形を防止できる。また、接着部材を真空断熱材側に付設することで、接着部材を効率的に使用することができる。
【００２４】
本発明の請求項９に記載の発明は、請求項８に記載の発明において、接着部材は真空断熱材に全面塗布したものである。
【００２５】
本発明によれば、全面塗布することにより接着力を高めることができるとともに、真空断熱材と外箱との間に空気層が生じず、真空断熱材接着面の外箱外観変形を防止できる。
【００２６】
本発明の請求項１０に記載の発明は、請求項９に記載の発明において、真空断熱材に塗付する接着部材は、対向して回転するローラの一方に接着部材を付着させ、ローラ間に真空断熱材を通して行なうものである。
【００２７】
本発明によれば、ローラを用いることで接着部材を真空断熱材に均一に過不足なく塗付することができる。また、塗付作業の効率向上が図れる。
【００２８】
本発明の請求項１１に記載の発明は、請求項９または１０に記載の発明において、接着部材はゲル状のホットメルトとしたものである。
【００２９】
本発明によれば、ゲル状のホットメルトが、真空断熱材の表面の凹凸、そり等の外箱変形要因を吸収し、外箱外表面の変形を防止できる。
【００３０】
本発明の請求項１２に記載の発明は、請求項９から請求項１１のいずれか一項に記載の発明において、接着部材はゲル状で硬化型の接着材としたものである。
【００３１】
本発明によれば、ゲル状で硬化型の接着材を用いることで、接着後の真空断熱材のズレ、剥がれが生じず接着信頼性が高まる。
【００３２】
本発明の請求項１３に記載の発明は、外箱と内箱の間に硬質ウレタンフォームと真空断熱材とを備えた断熱箱体の製造において、硬質ウレタンフォーム発泡完了後に、前記真空断熱材が所定の位置で所定の断熱性能を維持しているかを検査する検査工程を行なうものである。
【００３３】
本発明によれば、検査工程を行なうことで、断熱箱体の不具合を事前に発見でき、不良品の出荷を未然に防ぐことができる。
【００３４】
本発明の請求項１４に記載の発明は、請求項１３に記載の発明において、検査工程は打音による聴音での検査としたものである。
【００３５】
本発明によれば、真空断熱材が所定の位置に配置しているかを打音検査により簡単に確認することができる。
【００３６】
本発明の請求項１５に記載の発明は、請求項１３に記載の発明において、検査工程はサーモグラフィー装置による表面温度での検査としたものである。
【００３７】
本発明によれば、真空断熱材が所定の位置で、所定の断熱性能を保持しているかをサーモグラフィー装置を用い外箱の表面温度を視覚で判断することにより非接触で簡単に確認することができる。
【００３８】
本発明の請求項１６に記載の発明は、請求項１から請求項１５のいずれか一項に記載の断熱箱体の製造方法により製造した断熱箱体を用いた冷蔵庫としたものである。
【００３９】
本発明によれば、真空断熱材を用いた高い断熱性能を有する断熱箱体を用いることにより、消費電力量の少ない冷蔵庫を提供できる。
【００４０】
【発明の実施の形態】
以下、本発明の実施の形態について、図面を参照しながら説明する。
【００４１】
（実施の形態１）
図１は、本発明の実施の形態１における冷蔵庫の断熱箱体の外箱を折り曲げる前の状態を示す斜視図、図２は、同実施の形態の冷蔵庫の断熱箱体の外箱を折り曲げた後の状態を示す斜視図、図３は同実施の形態の冷蔵庫の断熱箱体の外箱に真空断熱材を貼り付けた状態を示す斜視図、図４は、同実施の形態の冷蔵庫の断熱箱体の製造工程を示す工程図、図５は、同実施の形態の冷蔵庫の断熱箱体の外箱に真空断熱材を貼り付ける冶具を示す平面図、図６は、同実施の形態の冷蔵庫の断熱箱体の外箱に真空断熱材を貼り付ける冶具の要部斜視図、図７、図８は、同実施の形態の冷蔵庫に用いる真空断熱材に接着部材を塗付する装置を示す概要図、図９、図１０は、同実施の形態の冷蔵庫の断熱箱体の外箱に真空断熱材を貼り付ける工程を示す要部平面図ある。
【００４２】
図１〜図４において、１０は鋼板からなる外板で平板状を成し、外板１０の長手方向の端部にフランジ１１を形成し、折り曲げ部にあらかじめＶカット１２を施すプレス工程を行なう（Ｓ４）。そして、冶具（図示せず）を用いて、Ｖカット１２を折り曲げ部として折り曲げコの字状とし、冷蔵庫の断熱箱体の外箱１０の側面１３および天面１４を構成する折り曲げ工程を行なう（Ｓ５）。その後、真空断熱材貼付冶具１８を用い真空断熱材１５、１６、１７を断熱箱体の外箱１０の側面１３および天面１４に貼り付ける真空断熱材貼り付け工程を行なう（Ｓ６）。そして、真空断熱材１５、１６、１７を内面に貼り付けた外箱１０と内箱（図示せず）を係合して形成された空間内に硬質ウレタンフォーム（図示せず）を充填し、発泡するウレタン発泡工程を行ない断熱箱体を完成する（Ｓ７）。
【００４３】
図５において、真空断熱材貼付冶具１８は、外冶具１９と内冶具２０とより成り、内冶具２０は側面冶具２１、２２と天面冶具２３とより成る。側面冶具２１、２２と天面冶具２３は可動装置２４の連結バー２５を介して可動する。
【００４４】
図６において、２６は、側面冶具２１の真空断熱材１５固定側に設けたＬ型支持部である。
【００４５】
図７、図８において、２７は上ローラ、２８は下ローラで、それぞれ円筒形状を成し、軸２９、３０を中心に対向して回転する。３１は容器で内部に接着部材３２を有している。そして、下ローラ２８は容器３１内の接着部材３２に一部が漬かるように配置している。また、上ローラ２７と下ローラ２８の間隔Ａは真空断熱材１５の厚みｔよりも若干小さく設定している。また、上ローラ２７と下ローラ２８の表面は軟質部材たとえば多孔質樹脂発泡体、スポンジなどで構成され、接着部材３２を表面に保持しやすいようにしている。また、上ローラ２７と下ローラ２８は、手動あるいは自動で駆動させるものである。上記、上ローラ２７、下ローラ２８、容器３１、接着部材３２より、接着部材塗布装置３３は構成している。
【００４６】
なお、接着部材３２としてはゲル状のホットメルトとしている。
上記構成において、以下動作について説明する。
【００４７】
ライン上を流れてきた鋼板からなる外板１０は、プレス工程（Ｓ４）によりＶカット１２を施し、複数のロールフォーマー（図示せず）によりフランジ１１を形成する。その後、折り曲げ工程（Ｓ５）にて、冶具（図示せず）を用いて、Ｖカット１２を折り曲げ部として折り曲げコの字状とし、冷蔵庫の断熱箱体の外箱の側面１３および天面１４を構成する。コの字状とした外板１０はフランジ１１の前フランジ側を下方にして設置する。その後、真空断熱材貼り付け工程（Ｓ６）にて、真空断熱材貼付冶具１８を用い真空断熱材１５、１６、１７を断熱箱体の外箱の側面１３および天面１４に貼り付ける工程を行なう。そして、ウレタン発泡工程（Ｓ７）にて真空断熱材１５、１６、１７を内面に貼り付けた外箱１０と内箱（図示せず）を係合して形成された空間内に硬質ウレタンフォーム（図示せず）を充填し、発泡して断熱箱体を完成する。
【００４８】
したがって、外板１０を折り曲げた後に、真空断熱材１５、１６、１７を貼り付ける工程としたことにより、外板１０を折り曲げ前に真空断熱材を貼る工程に比べ、貼り付け作業スペースを小さくでき製造工程の作業空間の設置効率を高めることができる。また、折り曲げ時の衝撃により真空断熱材が剥がれる問題も生じない。
【００４９】
次に、真空断熱材貼り付け工程について、詳細を説明する。
【００５０】
真空断熱材１５は接着部材塗付装置３３の上ローラ２７と下ローラ２８の間に挟み込み、各ローラの回転により前方に進む。そして下ローラ２８の表面に保持された接着部材３２としてのゲル状のホットメルトが真空断熱材１５の片面に全面塗布される。このときローラを用いているので接着部材３２を真空断熱材１５に均一に過不足なく塗付することができる。また、接着部材塗付装置３３を用いることにより塗付作業の効率向上が図れる。
【００５１】
そして、接着部材３２を片面に全面塗布された真空断熱材１５は、真空断熱材貼付冶具１８の内冶具２０の側面冶具２１に仮固定される。このとき接着部材３２側を外側に向けＬ型支持部２６に端辺を合わせて置く。
【００５２】
また、フランジ１１の前フランジ側を下方にして設置したコの字状の外板１０の外周を覆うように外冶具１９が設置される。そして、天面１４に対向した開放側より真空断熱材貼付冶具１８を外板１０の内側に挿入し、可動装置２４の連結バー２５の動作により、真空断熱材１５は冷蔵庫の断熱箱体の外箱の側面１３に貼り付けられる。このとき図９に示すように、真空断熱材１５を載せた側面冶具２１は側面１３に対して一端を先に接触させる。その後、図１０に示すように、真空断熱材１５の一端を接触させた面から順次、外箱の側面１３の貼り付け面に圧設する。
【００５３】
したがって、真空断熱材１５を、外冶具１９と内冶具２０とからなる真空断熱材貼付冶具１８で外板１０の内側に貼り付けることにより、非定常な作業がなくなり真空断熱材の破損を防止できる。また、真空断熱材貼付冶具１８により真空断熱材１５の貼り付け位置の位置決めが確実となり、貼り付けバラツキを抑えることができる。また、一度に複数の真空断熱材を複数の面に貼り付け可能となり、製造工程の生産効率を高めることができる。
【００５４】
また、真空断熱材貼付冶具１８は、外冶具１９と内冶具２０とで外板１０の貼り付け部を内側と外側からの２平面で挟み込む方式としたので、真空断熱材１５貼り付け時、押さえる圧力を均一化でき、真空断熱材１５の接着面の外箱外観変形を防止できる。
【００５５】
また、真空断熱材１５を真空断熱材貼付冶具１８のＬ型支持部２６に端辺を合わせて取付けることで、位置決めが確実になるとともに、冶具への支持作業が容易となり製造工程の生産効率を高めることができる。
【００５６】
また、真空断熱材貼付冶具１８は真空断熱材１５の一端を接触させた面から順次、外箱の側面１３の貼り付け面に圧設するものであり、真空断熱材１５と外板１０の貼付面との間に空気層が生じず、真空断熱材接着面の外箱外観変形を防止できる。
【００５７】
また、真空断熱材１５と外板１０とを接着する接着部材３２は、真空断熱材１５側に塗付しているので、真空断熱材１５の表面の凹凸、そり等の外箱変形要因を接着部材３２の厚みが吸収して外箱外表面の変形を防止できる。また、接着部材を真空断熱材側に付設することで、接着部材を効率的に使用することができる。
【００５８】
また、接着部材３２は真空断熱材１５に全面塗布しているので、真空断熱材１５と外板１０との接着力を高めることができるとともに、真空断熱材１５と外板１０との間に空気層が生じず、真空断熱材１５の接着面の外箱外観変形を防止できる。
【００５９】
また、接着部材３２はゲル状のホットメルトとしたので、真空断熱材１５の表面の凹凸、そり等の外箱変形要因を吸収し、外箱外表面の変形を防止できる。
【００６０】
なお、接着部材３２はゲル状で硬化型の接着材としてもよい。この場合、接着後の真空断熱材１５のズレ、剥がれが生じず接着信頼性が高まる。
【００６１】
また、真空断熱材貼付冶具１８のＬ型支持部２６を構成する端辺は少なくとも側面冶具２１の下部に設けている。これにより、真空断熱材１５の支持が確実になる。さらに、コの字状とした外板１０のフランジ１１の前フランジ側を下方にして設置した状態で、真空断熱材１５を貼り付けることで前フランジ側のフランジ部から真空断熱材１５の離間距離を一定にできる。つまり、前フランジ側のフランジ部には放熱パイプなどを配設できるように端部の曲げ、切り起しがあり、その端面で真空断熱材１５を破損させてしまう危険性があるが、上述したように位置決めを確実にできるので、破損の危険性が生じない。
【００６２】
また、真空断熱材貼付冶具１８の動作は、手動式でも自動式でもよい。
【００６３】
また、本実施の形態では、真空断熱材１５を外箱の側面１３に貼り付ける場合について説明したが、天面１４に貼り付ける場合も同様であり、同様の効果を有する。
【００６４】
また、真空断熱材貼付冶具１８は真空断熱材１５の一端を接触させた面から順次、一方向から外箱の側面１３の貼り付け面に圧設するものであるが、その方向は、前後、上下方向どちらからでもよい。
【００６５】
（実施の形態２）
図１１、図１２は、本発明の実施の形態２による断熱箱体の製造方法の概要図である。なお、実施の形態１と同一部分については、詳細な説明を省略し、異なる部分についてのみ説明する。
【００６６】
真空断熱材貼り付け工程（Ｓ６）において、３３は外板１０の側面１３と真空断熱材１５との間に配置する介在部材で、介在部材３３は真空断熱材１５よりも軟らかい軟質部材としている。また、介在部材３３の貼り方は、図１１に示すように、あらかじめ外箱外表面の変形を防止する介在部材３３を側面１３に配設した後、真空断熱材１５を外箱に貼り付けるものである。
【００６７】
上記構成により、真空断熱材１５と外板１０の側面１３との間の介在部材３３が真空断熱材１５の表面の凹凸、そり等の外箱変形要因を吸収し、外箱外表面の変形を防止できる。また、介在部材３３をあらかじめ外板１０の側面１３側に配設しておくことで、組立工程での生産効率を高めることができる。
【００６８】
また、介在部材３３は真空断熱材１５よりも軟らかい軟質部材としているので、真空断熱材１５の表面の凹凸、そり等の外箱変形要因の吸収を軟質部材が行い、外箱外表面の変形を確実に防止できる。
【００６９】
なお、図１２に示すように、あらかじめ外箱外表面の変形を防止する介在部材３４を真空断熱材１５に配設した後、真空断熱材１５を外箱に貼り付けてもよい。この場合、真空断熱材と外箱との間の介在部材が真空断熱材の表面の凹凸、そり等の外箱変形要因を吸収し、外箱外表面の変形を防止できるとともに、介在部材３４をあらかじめ真空断熱材１５に配設しておくことで、組立工程での生産効率を高めることができる。
【００７０】
また、介在部材３４は真空断熱材１５よりも硬い硬質部材としてもよい。この場合、真空断熱材１５の表面の凹凸、そり等の外箱変形要因が外箱外表面に伝わることを防止でき、外箱外表面の変形を防止できる。
【００７１】
（実施の形態３）
図１３は、本発明の実施の形態３による冷蔵庫における検査工程を示す概略図である。なお、実施の形態１または２と同一部分については、詳細な説明を省略し、異なる部分についてのみ説明する。
【００７２】
図において、３５は、外箱に真空断熱材を実施の形態１または２の断熱箱体の製造方法により組み込み、その後、外箱と内箱の間に硬質ウレタンフォームを発泡し、その後、圧縮機、凝縮器、減圧装置、蒸発器、等の冷凍サイクル部品を組み込んだ冷蔵庫である。３６は打音装置で、硬質ウレタンフォーム発泡後、真空断熱材が所定の位置で所定の断熱性能を維持しているかを検査する検査工程で用いられる。具体的には、外板１０に真空断熱材１５、１６、１７を貼り付けた外箱外表面に打音装置３６を当てることにより、真空断熱材１５、１６、１７が硬質ウレタンフォーム発泡前に貼付面から脱落などで正規の位置にない場合と正規の位置にある場合との打音時の音質の差を聞き分けて有無の判断をする。また、たとえ正規の位置に配置していても、真空断熱材１５、１６、１７の破れ、破損等による真空度不良（断熱性能不良）の場合においても、打音時の音質の差を聞き分けて判断をすることができる。
【００７３】
なお、打音検査は、外板１０に限定するものではなく、真空断熱材が貼られた個所を行なうことが望ましい。
【００７４】
また、冷蔵庫３５は、一枚の平板１０を折り曲げて外箱の側面および天面を構成するとともに真空断熱材１５、１６、１７は平板を折り曲げた後に外箱に貼り付け、その後、外箱と内箱の間に硬質ウレタンフォームを発泡し、その後、圧縮機、凝縮器、減圧装置、蒸発器、等の冷凍サイクル部品を組み込んだものであり、真空断熱材を用いた高い断熱性能を有する断熱箱体を用いることにより、消費電力量の少ない冷蔵庫を提供できる。
【００７５】
（実施の形態４）
図１４は、本発明の実施の形態４による冷蔵庫における検査工程を示す概略図である。なお、実施の形態１または２と同一部分については、詳細な説明を省略し、異なる部分についてのみ説明する。
【００７６】
図において、３７は、外箱に真空断熱材を実施の形態１または２の断熱箱体の製造方法により組み込み、その後、外箱と内箱の間に硬質ウレタンフォームを発泡し、その後、圧縮機、凝縮器、減圧装置、蒸発器、等の冷凍サイクル部品を組み込んだ冷蔵庫である。３８は赤外線を用いて非接触で表面温度を測定できるサーモグラフィー装置で、内部を一定温度に保った部屋３９内に設置し、硬質ウレタンフォーム発泡後、真空断熱材が所定の位置で所定の断熱性能を維持しているかを検査する検査工程で用いられる。具体的には、冷蔵庫を運転しながら、外板１０に真空断熱材１５、１６、１７を貼り付けた外箱外表面にサーモグラフィー装置のカメラを合わせ、その画像データ（温度分布）により、真空断熱材１５、１６、１７の配設の不具合を検査する。たとえば、不正規の場合、断熱性能が低下しており、表面温度は低くなる。
したがって、冷蔵庫本体に非接触で、簡単に確実に真空断熱材１５、１６、１７の配設、あるいは、不良状態を検査することができる。
【００７７】
【発明の効果】
以上説明したように請求項１記載の発明は、外箱と内箱の間に硬質ウレタンフォームと真空断熱材とを備えた断熱箱体の製造において、一枚の平板を折り曲げて前記外箱の側面および天面を構成する折り曲げ工程と、前記折り曲げ工程後に外冶具と内冶具を用いて内側と外側からの２平面で挟み込み、真空断熱材を前記外箱の内面に貼り付ける真空断熱材貼り付け工程と、前記外箱に前記内箱を係合して形成された前記真空断熱材を有する空間内に前記硬質ウレタンフォームを充填，発泡させる工程とよりなるものであり、貼り付け作業スペースを小さくでき製造工程の作業空間の設置効率を高めることができる。また、折り曲げ時の衝撃により真空断熱材が剥がれる問題も生じない。また、非定常な作業がなくなり作業者による真空断熱材の破損を防止できる。また、冶具により真空断熱材の貼り付け位置の位置決めが確実となり、貼り付けバラツキを抑えることができる。また、一度に複数の真空断熱材を複数の面に貼り付け可能となり、製造工程の生産効率を高めることができる。また、外箱の貼り付け部を内側と外側からの２平面で挟み込むことで、真空断熱材貼り付け時、押さえる圧力を均一化でき、真空断熱材接着面の外箱外観変形を防止できる。
【００７８】
また、本発明の請求項２に記載の発明は、請求項１に記載の発明において、内冶具は、真空断熱材の端部二辺をＬ型支持部で支持するものであり、真空断熱材の内冶具への支持が確実になるとともに、内冶具への支持作業が容易となり製造工程の生産効率を高めることができる。
【００７９】
また、本発明の請求項３に記載の発明は、請求項１または請求項２に記載の発明において、内冶具は、真空断熱材支持面が一方向から順次外箱の貼り付け面に圧設するものであり、真空断熱材と外箱との間に空気層が生じず、真空断熱材接着面の外箱外観変形を防止できる。
【００８０】
また、本発明の請求項４に記載の発明は、外箱と内箱の間に硬質ウレタンフォームと真空断熱材とを備えた断熱箱体の製造において、一枚の平板を折り曲げて前記外箱の側面および天面を構成する折り曲げ工程と、真空断熱材を外箱に貼り付ける真空断熱材貼り付け工程とよりなり、前記真空断熱材貼り付け工程において、真空断熱材に外箱外表面の変形を防止する介在部材をあらかじめ配設した後に、介在部材側を外箱に貼り付けるものであり、真空断熱材と外箱との間の介在部材が真空断熱材の表面の凹凸、そり等の外箱変形要因を吸収し、外箱外表面の変形を防止できる。また、介在部材をあらかじめ真空断熱材に配設しておくことで、組立工程での生産効率を高めることができる。
【００８１】
また、本発明の請求項５に記載の発明は、外箱と内箱の間に硬質ウレタンフォームと真空断熱材とを備えた断熱箱体の製造において、一枚の平板を折り曲げて前記外箱の側面および天面を構成する折り曲げ工程と、真空断熱材を外箱に貼り付ける真空断熱材貼り付け工程とよりなり、前記真空断熱材貼り付け工程において、外箱側に外箱外表面の変形を防止する介在部材をあらかじめ配設した後に、真空断熱材を外箱に貼り付けるものであり、真空断熱材と外箱との間の介在部材が真空断熱材の表面の凹凸、そり等の外箱変形要因を吸収し、外箱外表面の変形を防止できる。また、介在部材をあらかじめ外箱側に配設しておくことで、組立工程での生産効率を高めることができる。
【００８２】
また、本発明の請求項６に記載の発明は、請求項４または５に記載の発明において、介在部材は真空断熱材よりも軟らかい軟質部材としたものであり、真空断熱材の表面の凹凸、そり等の外箱変形要因の吸収を軟質部材が行い、外箱外表面の変形を確実に防止できる。
【００８３】
また、本発明の請求項７に記載の発明は、請求項４または５に記載の発明において、介在部材は真空断熱材よりも硬い硬質部材としたものであり、真空断熱材の表面の凹凸、そり等の外箱変形要因が外箱外表面に伝わることを防止でき、外箱外表面の変形を防止できる。
【００８４】
また、本発明の請求項８に記載の発明は、請求項１から請求項７のいずれか一項に記載の発明において、真空断熱材と外箱との接着部材は、真空断熱材側に付設するものであり、真空断熱材の表面の凹凸、そり等の外箱変形要因を接着部材の厚みが吸収して外箱外表面の変形を防止できる。また、接着部材を真空断熱材側に付設することで、接着部材を効率的に使用することができる。
【００８５】
また、本発明の請求項９に記載の発明は、請求項８に記載の発明において、接着部材は真空断熱材に全面塗布したものであり、接着力を高めることができるとともに、真空断熱材と外箱との間に空気層が生じず、真空断熱材接着面の外箱外観変形を防止できる。
【００８６】
また、本発明の請求項１０に記載の発明は、請求項９に記載の発明において、真空断熱材に塗付する接着部材は、対向して回転するローラの一方に接着部材を付着させ、ローラ間に真空断熱材を通して行なうものであり、接着部材を真空断熱材に均一に過不足なく塗付することができる。また、塗付作業の効率向上が図れる。
【００８７】
また、本発明の請求項１１に記載の発明は、請求項９または１０に記載の発明において、接着部材はゲル状のホットメルトとしたものであり、ゲル状のホットメルトが真空断熱材の表面の凹凸、そり等の外箱変形要因を吸収し、外箱外表面の変形を防止できる。
【００８８】
また、本発明の請求項１２に記載の発明は、請求項９から請求項１１のいずれか一項に記載の発明において、接着部材はゲル状で硬化型の接着材としたものであり、接着後の真空断熱材のズレ、剥がれが生じず接着信頼性が高まる。
【００８９】
また、本発明の請求項１３に記載の発明は、外箱と内箱の間に硬質ウレタンフォームと真空断熱材とを備えた断熱箱体において、硬質ウレタンフォーム発泡完了後に、前記真空断熱材が所定の位置で所定の断熱性能を維持しているかを検査する検査工程を行なうものであり、断熱箱体の不具合を事前に発見でき、不良品の出荷を未然に防ぐことができる。
【００９０】
また、本発明の請求項１４に記載の発明は、請求項１３に記載の発明において、検査工程は打音による聴音での検査としたものであり、真空断熱材が所定の位置に配置しているかを簡単に確認することができる。
【００９１】
また、本発明の請求項１５に記載の発明は、請求項１３に記載の発明において、検査工程はサーモグラフィー装置による表面温度での検査としたものであり、真空断熱材が所定の位置で、所定の断熱性能を保持しているかをサーモグラフィー装置を用い外箱の表面温度を視覚で判断することにより非接触で簡単に確認することができる。
【００９２】
また、本発明の請求項１６に記載の発明は、請求項１から請求項１５のいずれか一項に記載の断熱箱体の製造方法により製造した断熱箱体を用いた冷蔵庫とすることにより、消費電力量の少ない冷蔵庫や断熱壁厚を薄くして外容積に対する内容積効率を高めた冷蔵庫を提供できる。
【図面の簡単な説明】
【図１】本発明の実施の形態１における冷蔵庫の断熱箱体の外箱を折り曲げる前の状態を示す斜視図
【図２】同実施の形態の冷蔵庫の断熱箱体の外箱を折り曲げた後の状態を示す斜視図
【図３】同実施の形態の冷蔵庫の断熱箱体の外箱を折り曲げた後の状態を示す斜視図
【図４】同実施の形態の冷蔵庫の断熱箱体の製造工程を示す工程図
【図５】同実施の形態の冷蔵庫の断熱箱体の外箱に真空断熱材を貼り付ける冶具を示す平面図
【図６】同実施の形態の冷蔵庫の断熱箱体の外箱に真空断熱材を貼り付ける冶具の要部斜視図
【図７】同実施の形態の冷蔵庫に用いる真空断熱材に接着部材を塗付する装置を示す概要図
【図８】同実施の形態の冷蔵庫に用いる真空断熱材に接着部材を塗付する装置を示す概要図
【図９】同実施の形態の冷蔵庫の断熱箱体の外箱に真空断熱材を貼り付ける工程を示す要部平面図
【図１０】同実施の形態の冷蔵庫の断熱箱体の外箱に真空断熱材を貼り付ける工程を示す要部平面図
【図１１】本発明の実施の形態２による断熱箱体の製造方法の概要図
【図１２】本発明の実施の形態２による断熱箱体の製造方法の概要図
【図１３】本発明の実施の形態３による冷蔵庫における検査工程を示す概略図
【図１４】本発明の実施の形態４による冷蔵庫における検査工程を示す概略図
【図１５】従来の冷蔵庫の断熱箱体の外箱を折り曲げる前の状態を示す斜視図
【図１６】同冷蔵庫の断熱箱体の外箱に真空断熱材を貼り付けた状態を示す斜視図
【図１７】同冷蔵庫の断熱箱体の外箱を折り曲げた後の状態を示す斜視図
【図１８】同冷蔵庫の断熱箱体の折り曲げ工程を示す工程図
【符号の説明】
１０　外板
１３　側面
１４　天面
１５，１６，１７　真空断熱材
１８　真空断熱材貼付冶具
１９　外冶具
２０　内冶具
２１、２２　側面冶具
２３　天面冶具
２６　Ｌ型支持部
２７　上ローラ
２８　下ローラ
３２　接着部材
３３、３４　介在部材
３５、３７　冷蔵庫
３６　打音装置
３８　サーモグラフィー装置[0001]
TECHNICAL FIELD OF THE INVENTION
The present invention relates to a method for manufacturing a heat insulating box of a refrigerator using a vacuum heat insulating material.
[0002]
[Prior art]
In recent years, as a means of improving the heat insulating performance of refrigerators, there is a method of using a vacuum insulating material having high heat insulating performance in order to save energy and space of the refrigerator. It is urgently necessary to improve the heat insulating performance by maximizing the use of a vacuum heat insulating material having a heat insulating performance several to ten times that of the foam within an appropriate range. As a method for manufacturing a heat insulating box of a refrigerator having high heat insulating performance using a vacuum heat insulating material, Japanese Patent Application Laid-Open No. 7-98090 is known.
[0003]
FIG. 15 is a perspective view showing a state before the outer box of the heat insulating box of the conventional refrigerator is bent, and FIG. 16 is a perspective view showing a state where a vacuum heat insulating material is attached to the outer box of the heat insulating box of the refrigerator. 17 is a perspective view showing a state after the outer box of the heat insulating box of the refrigerator is bent, and FIG. 18 is a process diagram showing a bending step of the heat insulating box of the refrigerator.
[0004]
Hereinafter, a method for manufacturing the above-described conventional heat insulating box of a refrigerator will be described with reference to the drawings.
[0005]
Reference numeral 1 denotes a flat plate made of a steel plate. A flange 2 is formed at an end of the flat plate 1 in the longitudinal direction, and a V-cut 3 is applied to a bent portion in advance (S1). Then, the vacuum heat insulating materials 4, 5, and 6 are attached to the flat plate 1 (S2). Then, using a jig, the V-cut 3 is bent as a bent portion to form the side surface and the top surface of the heat insulating box of the refrigerator (S3). After that, the inner box, back plate, and bottom plate are assembled, filled with hard urethane foam, foamed and vacuum heat insulating material is applied to manufacture a refrigerator heat insulating box having high heat insulating performance.
[0006]
[Problems to be solved by the invention]
However, in the refrigerator manufacturing method described in the conventional example, since the vacuum heat insulating materials 4, 5, and 6 are bent after being attached to the flat plate 1, the vacuum heat insulating materials 4, 5, and 6 are impacted by the bending. Peeling may occur. Further, when the vacuum heat insulating materials 4, 5, 6 are attached to the flat plate 1, a relatively long operation time is required, so that the work space for attaching the vacuum heat insulating materials 4, 5, 6 to the flat plate 1 must be increased. However, there is a problem that the installation efficiency of the work space in the manufacturing process is reduced.
[0007]
The present invention has been made in view of the above problems, and provides a method for manufacturing a heat insulating box of a refrigerator, which is highly reliable and saves a work space in a manufacturing process, and a refrigerator.
[0008]
[Means for Solving the Problems]
The invention according to claim 1 of the present invention is directed to a method for manufacturing a heat insulating box having a rigid urethane foam and a vacuum heat insulating material between an outer box and an inner box, wherein one flat plate is bent to form a side surface of the outer box. And a bending step of forming a top surface, and a vacuum heat insulating material attaching step of sandwiching the inner surface of the outer box with the vacuum heat insulating material by sandwiching the inner surface with the inner and outer surfaces using an outer jig and an inner jig after the bending step. And filling and foaming the rigid urethane foam in a space having the vacuum heat insulating material formed by engaging the inner box with the outer box.
[0009]
According to the present invention, by attaching the vacuum heat insulating material to the outer box after bending the flat plate, the attaching work space can be reduced, and the installation efficiency of the work space in the manufacturing process can be increased. Further, there is no problem that the vacuum heat insulating material is peeled off by the impact at the time of bending. In addition, by attaching the vacuum heat insulating material using a jig, irregular work is eliminated, and damage to the vacuum heat insulating material can be prevented. In addition, the positioning of the position where the vacuum heat insulating material is to be attached is ensured by the jig, and the variation in attachment can be suppressed. Further, a plurality of vacuum heat insulating materials can be attached to a plurality of surfaces at one time, so that the production efficiency of the manufacturing process can be improved. In addition, the outer jig and the inner jig use a method in which the sticking part of the outer box is sandwiched between two planes from the inside and the outside. The appearance of the outer box can be prevented from being deformed.
[0010]
According to a second aspect of the present invention, in the first aspect, the inner jig supports two ends of the vacuum heat insulating material with an L-shaped support.
[0011]
According to the present invention, since the vacuum heat insulating material is supported by the L-shaped support portion, the support to the jig is ensured, and the work of supporting the jig is facilitated, so that the production efficiency of the manufacturing process can be increased.
[0012]
According to a third aspect of the present invention, in the first or second aspect of the present invention, the inner jig has a vacuum insulation material supporting surface which is sequentially press-fitted from one direction to a bonding surface of the outer box. It is.
[0013]
ADVANTAGE OF THE INVENTION According to this invention, an air layer does not generate | occur | produce between a vacuum heat insulating material and an outer box, and can prevent outer box external deformation of a vacuum heat insulating material adhesion surface.
[0014]
The invention according to claim 4 of the present invention is directed to a method of manufacturing a heat insulating box provided with a rigid urethane foam and a vacuum heat insulating material between an outer box and an inner box. And a bending step of forming a top surface, and a vacuum heat insulating material sticking step of sticking the vacuum heat insulating material to the outer case. In the vacuum heat insulating material sticking step, the vacuum heat insulating material prevents deformation of the outer case outer surface. After arranging the intervening member in advance, the intervening member side is attached to the outer box.
[0015]
ADVANTAGE OF THE INVENTION According to this invention, the interposition member between a vacuum heat insulating material and an outer case can absorb the deformation | transformation factor of the outer case, such as unevenness | corrugation of the surface of a vacuum heat insulating material, and a warp, and can prevent the deformation of the outer surface of an outer case. In addition, by providing the intervening member on the vacuum heat insulating material in advance, the production efficiency in the assembly process can be increased.
[0016]
The invention according to claim 5 of the present invention is directed to a method of manufacturing a heat insulating box provided with a rigid urethane foam and a vacuum heat insulating material between an outer box and an inner box. And a bending step of forming a top surface, and a vacuum heat insulating material sticking step of sticking the vacuum heat insulating material to the outer box. In the vacuum heat insulating material sticking step, deformation of the outer box outer surface is prevented on the outer box side. After arranging the intervening member in advance, the vacuum heat insulating material is attached to the outer box.
[0017]
ADVANTAGE OF THE INVENTION According to this invention, the interposition member between a vacuum heat insulating material and an outer case can absorb the deformation | transformation factor of the outer case, such as unevenness | corrugation of the surface of a vacuum heat insulating material, and a warp, and can prevent the deformation of the outer surface of an outer case. Further, by arranging the intervening member on the outer box side in advance, it is possible to increase the production efficiency in the assembling process.
[0018]
According to a sixth aspect of the present invention, in the fourth or fifth aspect, the interposed member is a soft member softer than the vacuum heat insulating material.
[0019]
ADVANTAGE OF THE INVENTION According to this invention, a soft member absorbs the deformation | transformation factor of the outer case, such as unevenness | corrugation of the surface of a vacuum heat insulating material, and warpage, and can prevent deformation of the outer surface of an outer case reliably.
[0020]
The invention according to claim 7 of the present invention is the invention according to claim 4 or 5, wherein the interposed member is a hard member harder than the vacuum heat insulating material.
[0021]
According to the present invention, by using a hard member that is harder than the vacuum heat insulating material as the intervening member, it is possible to prevent irregularities on the surface of the vacuum heat insulating material, deformation factors of the outer box such as warpage from being transmitted to the outer surface of the outer box, Deformation of the outer surface of the box can be prevented.
[0022]
The invention according to claim 8 of the present invention is the invention according to any one of claims 1 to 7, wherein the adhesive member between the vacuum heat insulating material and the outer box is attached to the vacuum heat insulating material side. It is.
[0023]
ADVANTAGE OF THE INVENTION According to this invention, the deformation | transformation of the outer surface of an outer box can be prevented by the thickness of an adhesive member absorbing the outer box deformation factors, such as unevenness | corrugation of the surface of a vacuum heat insulating material, and warpage. Further, by providing the adhesive member on the vacuum heat insulating material side, the adhesive member can be used efficiently.
[0024]
According to a ninth aspect of the present invention, in the eighth aspect, the adhesive member is applied to the entire surface of the vacuum heat insulating material.
[0025]
ADVANTAGE OF THE INVENTION According to this invention, while applying the whole surface, adhesive force can be improved and an air layer does not generate | occur | produce between a vacuum heat insulating material and an outer box, and can prevent outer-box appearance deformation of a vacuum heat insulating material adhesion surface.
[0026]
According to a tenth aspect of the present invention, in the ninth aspect of the present invention, the adhesive member applied to the vacuum heat insulating material is formed by attaching the adhesive member to one of the oppositely rotating rollers, and between the rollers. This is done through vacuum insulation.
[0027]
ADVANTAGE OF THE INVENTION According to this invention, an adhesive member can be uniformly applied to a vacuum heat insulating material without excess or shortage by using a roller. Further, the efficiency of the coating operation can be improved.
[0028]
An eleventh aspect of the present invention is the invention according to the ninth or tenth aspect, wherein the adhesive member is a gel-like hot melt.
[0029]
ADVANTAGE OF THE INVENTION According to this invention, a gel-like hot melt absorbs the deformation | transformation factor of the outer box, such as unevenness | corrugation of the surface of a vacuum heat insulating material, and warpage, and can prevent the deformation of the outer surface of an outer box.
[0030]
According to a twelfth aspect of the present invention, in the invention according to any one of the ninth to eleventh aspects, the adhesive member is a gel-type curable adhesive.
[0031]
ADVANTAGE OF THE INVENTION According to this invention, the displacement of a vacuum heat insulating material after adhesion | attachment and peeling do not generate | occur | produce, but adhesion | attachment reliability increases by using a gel-like hardening type adhesive.
[0032]
The invention according to claim 13 of the present invention is characterized in that, in the production of a heat insulating box provided with a hard urethane foam and a vacuum heat insulating material between an outer box and an inner box, after the completion of the foaming of the hard urethane foam, the vacuum heat insulating material is An inspection step is performed for inspecting whether or not a predetermined heat insulating performance is maintained at a predetermined position.
[0033]
ADVANTAGE OF THE INVENTION According to this invention, a defect of a heat insulation box can be discovered beforehand by performing an inspection process, and shipment of a defective product can be prevented beforehand.
[0034]
According to a fourteenth aspect of the present invention, in the thirteenth aspect, the inspection step is an inspection based on a hearing sound by a tapping sound.
[0035]
According to the present invention, whether or not the vacuum heat insulating material is arranged at a predetermined position can be easily confirmed by a tapping sound inspection.
[0036]
According to a fifteenth aspect of the present invention, in the thirteenth aspect, the inspection step is an inspection at a surface temperature using a thermographic device.
[0037]
According to the present invention, it is possible to easily confirm non-contact simply by visually judging the surface temperature of the outer box using a thermographic device to determine whether the vacuum heat insulating material has a predetermined heat insulating performance at a predetermined position. it can.
[0038]
According to a sixteenth aspect of the present invention, there is provided a refrigerator using an insulated box manufactured by the method for manufacturing an insulated box according to any one of the first to fifteenth aspects.
[0039]
ADVANTAGE OF THE INVENTION According to this invention, the refrigerator with low power consumption can be provided by using the heat insulation box which has the high heat insulation performance using the vacuum heat insulating material.
[0040]
BEST MODE FOR CARRYING OUT THE INVENTION
Hereinafter, embodiments of the present invention will be described with reference to the drawings.
[0041]
(Embodiment 1)
FIG. 1 is a perspective view showing a state before the outer box of the heat insulating box of the refrigerator according to the first embodiment of the present invention is bent. FIG. 2 is a view showing the outer box of the heat insulating box of the refrigerator of the same embodiment. FIG. 3 is a perspective view showing a state after the vacuum heat insulating material is attached to the outer box of the heat insulating box of the refrigerator of the embodiment, and FIG. 3 is a perspective view showing the heat insulating of the refrigerator of the embodiment. FIG. 5 is a process diagram showing a manufacturing process of the box, FIG. 5 is a plan view showing a jig for attaching a vacuum heat insulating material to an outer box of the heat insulating box of the refrigerator of the embodiment, and FIG. 6 is a refrigerator of the embodiment. 7 and 8 are perspective views of a main part of a jig for attaching a vacuum heat insulating material to an outer box of the heat insulating box, and FIGS. 7 and 8 are schematic views showing an apparatus for applying an adhesive member to the vacuum heat insulating material used in the refrigerator of the embodiment. FIG. 9, FIG. 9, and FIG. 10 are main views showing a step of attaching a vacuum heat insulating material to the outer box of the heat insulating box of the refrigerator of the embodiment. There plan view.
[0042]
1 to 4, reference numeral 10 denotes an outer plate made of a steel plate, which is formed in a flat plate shape, a flange 11 is formed at an end in the longitudinal direction of the outer plate 10, and a pressing process is performed in which a bent portion is subjected to a V-cut 12 in advance. (S4). Then, using a jig (not shown), the V-cut 12 is bent into a U-shape as a bent portion, and a bending step of forming the side surface 13 and the top surface 14 of the outer box 10 of the heat insulating box body of the refrigerator is performed ( S5). Then, a vacuum heat insulating material attaching jig 18 is used to perform a vacuum heat insulating material attaching step of attaching the vacuum heat insulating materials 15, 16, 17 to the side surface 13 and the top surface 14 of the outer box 10 of the heat insulating box (S6). Then, a hard urethane foam (not shown) is filled in a space formed by engaging the outer box 10 having the vacuum heat insulating materials 15, 16, 17 adhered to the inner surface thereof and the inner box (not shown), A urethane foaming step for foaming is performed to complete a heat insulating box (S7).
[0043]
In FIG. 5, the vacuum heat insulating material attaching jig 18 includes an outer jig 19 and an inner jig 20, and the inner jig 20 includes side jigs 21 and 22 and a top jig 23. The side jigs 21 and 22 and the top jig 23 move via the connection bar 25 of the movable device 24.
[0044]
In FIG. 6, reference numeral 26 denotes an L-shaped support portion provided on the side of the side jig 21 on which the vacuum heat insulating material 15 is fixed.
[0045]
7 and 8, reference numeral 27 denotes an upper roller, and reference numeral 28 denotes a lower roller, each of which has a cylindrical shape and rotates around shafts 29 and 30. Reference numeral 31 denotes a container having an adhesive member 32 therein. The lower roller 28 is disposed so that a part thereof is immersed in the adhesive member 32 in the container 31. The distance A between the upper roller 27 and the lower roller 28 is set slightly smaller than the thickness t of the vacuum heat insulating material 15. The surfaces of the upper roller 27 and the lower roller 28 are made of a soft material such as a porous resin foam, sponge, or the like, so that the adhesive member 32 can be easily held on the surface. The upper roller 27 and the lower roller 28 are driven manually or automatically. The above-described upper roller 27, lower roller 28, container 31, and adhesive member 32 constitute an adhesive member application device 33.
[0046]
The adhesive member 32 is a gel-like hot melt.
The operation of the above configuration will be described below.
[0047]
The outer plate 10 made of a steel plate flowing on the line is subjected to a V-cut 12 in a press step (S4), and a flange 11 is formed by a plurality of roll formers (not shown). Thereafter, in a bending step (S5), the jig (not shown) is used to make the V cut 12 into a bent U-shape as a bent portion, and the side surface 13 and the top surface 14 of the outer box of the heat insulating box of the refrigerator are fixed. Constitute. The U-shaped outer plate 10 is installed with the front flange side of the flange 11 facing downward. Thereafter, in a vacuum heat insulating material sticking step (S6), a step of sticking the vacuum heat insulating materials 15, 16, 17 to the side surface 13 and the top surface 14 of the outer box of the heat insulating box using the vacuum heat insulating material sticking jig 18 is performed. . Then, in the urethane foaming step (S7), the hard urethane foam (in the space formed by engaging the inner box (not shown) and the outer box 10 with the vacuum heat insulating materials 15, 16, 17 attached to the inner surface thereof is formed. (Not shown) and foamed to complete the heat insulating box.
[0048]
Therefore, the step of attaching the vacuum heat insulating materials 15, 16, and 17 after bending the outer plate 10 can reduce the attaching work space as compared with the step of applying the vacuum heat insulating material before bending the outer plate 10. The installation efficiency of the work space in the manufacturing process can be improved. Further, there is no problem that the vacuum heat insulating material is peeled off by the impact at the time of bending.
[0049]
Next, the vacuum heat insulating material attaching step will be described in detail.
[0050]
The vacuum heat insulating material 15 is sandwiched between the upper roller 27 and the lower roller 28 of the adhesive member coating device 33, and advances forward by the rotation of each roller. Then, a gel-like hot melt as an adhesive member 32 held on the surface of the lower roller 28 is applied to the entire surface of one side of the vacuum heat insulating material 15. At this time, since a roller is used, the adhesive member 32 can be uniformly applied to the vacuum heat insulating material 15 without excess or shortage. Further, by using the adhesive member applying device 33, the efficiency of the applying operation can be improved.
[0051]
Then, the vacuum heat insulating material 15 having the adhesive member 32 applied on one surface thereof is temporarily fixed to the side jig 21 of the inner jig 20 of the vacuum heat insulating material sticking jig 18. At this time, the adhesive member 32 is placed outside with the edges thereof facing the L-shaped support portion 26.
[0052]
An outer jig 19 is installed so as to cover the outer periphery of the U-shaped outer plate 10 installed with the front flange side of the flange 11 facing downward. Then, the vacuum heat insulating material attaching jig 18 is inserted into the outer plate 10 from the open side facing the top surface 14, and the operation of the connecting bar 25 of the movable device 24 causes the vacuum heat insulating material 15 to move outside the heat insulating box of the refrigerator. Affixed to the side 13 of the box. At this time, as shown in FIG. 9, one end of the side jig 21 on which the vacuum heat insulating material 15 is placed is brought into contact with the side surface 13 first. Thereafter, as shown in FIG. 10, the vacuum heat insulating material 15 is sequentially press-fitted onto the surface to which the side surface 13 of the outer box is attached, starting from the surface with which one end of the vacuum heat insulating material 15 is in contact.
[0053]
Therefore, by attaching the vacuum heat insulating material 15 to the inside of the outer plate 10 with the vacuum heat insulating material sticking jig 18 composed of the outer jig 19 and the inner jig 20, unsteady work is eliminated, and breakage of the vacuum heat insulating material can be prevented. . In addition, the positioning of the position where the vacuum heat insulating material 15 is to be adhered is ensured by the vacuum heat insulating material bonding jig 18, so that it is possible to suppress the variation in the bonding. Further, a plurality of vacuum heat insulating materials can be attached to a plurality of surfaces at one time, so that the production efficiency of the manufacturing process can be improved.
[0054]
Further, the vacuum heat insulating material sticking jig 18 has a system in which the outer plate 10 is sandwiched between the outer jig 19 and the inner jig 20 by two planes from the inside and the outside. The pressure can be made uniform and the outer surface of the outer surface of the bonding surface of the vacuum heat insulating material 15 can be prevented from being deformed.
[0055]
In addition, by attaching the vacuum heat insulating material 15 to the L-shaped support portion 26 of the vacuum heat insulating material attaching jig 18 with its edges aligned, the positioning is ensured, and the supporting work on the jig is facilitated, and the production efficiency of the manufacturing process is improved. Can be enhanced.
[0056]
Further, the vacuum heat insulating material attaching jig 18 is for press-fitting the vacuum heat insulating material 15 to the outer plate 10 sequentially from the surface where one end of the vacuum heat insulating material 15 is brought into contact. An air layer is not formed between the outer surface and the outer surface of the outer surface of the vacuum heat insulating material bonding surface.
[0057]
Further, since the bonding member 32 for bonding the vacuum heat insulating material 15 and the outer plate 10 is applied on the vacuum heat insulating material 15 side, the outer box deformation factors such as unevenness and warpage of the surface of the vacuum heat insulating material 15 are bonded. The thickness of the member 32 is absorbed to prevent deformation of the outer surface of the outer box. Further, by providing the adhesive member on the vacuum heat insulating material side, the adhesive member can be used efficiently.
[0058]
Further, since the adhesive member 32 is applied to the entire surface of the vacuum heat insulating material 15, the adhesive strength between the vacuum heat insulating material 15 and the outer plate 10 can be increased, and the air between the vacuum heat insulating material 15 and the outer plate 10 can be increased. No layer is formed, and it is possible to prevent deformation of the outer surface of the outer box on the bonding surface of the vacuum heat insulating material 15.
[0059]
Further, since the adhesive member 32 is a gel-like hot melt, it can absorb the deformation factors of the outer box such as unevenness and warpage of the surface of the vacuum heat insulating material 15 and prevent the outer surface of the outer box from being deformed.
[0060]
Note that the adhesive member 32 may be a gel-type curable adhesive. In this case, the vacuum heat insulating material 15 after bonding is not displaced or peeled off, and the bonding reliability is improved.
[0061]
In addition, the edge of the L-shaped support portion 26 of the vacuum heat insulating material attaching jig 18 is provided at least below the side jig 21. Thereby, the support of the vacuum heat insulating material 15 is ensured. Further, in a state in which the front flange side of the flange 11 of the U-shaped outer plate 10 is installed with the front flange side downward, the vacuum heat insulating material 15 is attached to separate the vacuum heat insulating material 15 from the flange portion on the front flange side. Can be kept constant. In other words, the end of the front flange side is bent or cut so that a heat radiating pipe or the like can be provided, and there is a risk that the vacuum heat insulating material 15 may be damaged at the end face. As a result, there is no danger of breakage.
[0062]
The operation of the vacuum heat insulating material attaching jig 18 may be manual or automatic.
[0063]
Further, in the present embodiment, the case where the vacuum heat insulating material 15 is attached to the side surface 13 of the outer box has been described. However, the case where the vacuum heat insulating material 15 is attached to the top surface 14 is also the same, and has the same effect.
[0064]
In addition, the vacuum heat insulating material attaching jig 18 is sequentially pressed from one side to the surface to which the side surface 13 of the outer box is adhered, starting from the surface where one end of the vacuum heat insulating material 15 is brought into contact. It may be from either up or down direction.
[0065]
(Embodiment 2)
11 and 12 are schematic diagrams of a method for manufacturing a heat insulating box according to Embodiment 2 of the present invention. Detailed description of the same parts as in the first embodiment will be omitted, and only different parts will be described.
[0066]
In the vacuum heat insulating material attaching step (S6), reference numeral 33 denotes an intervening member arranged between the side surface 13 of the outer plate 10 and the vacuum heat insulating material 15, and the interposed member 33 is a soft member softer than the vacuum heat insulating material 15. In addition, as shown in FIG. 11, the method of attaching the intervening member 33 is such that the intervening member 33 for preventing deformation of the outer surface of the outer box is disposed on the side surface 13 in advance, and then the vacuum heat insulating material 15 is attached to the outer box. It is.
[0067]
With the above configuration, the intervening member 33 between the vacuum heat insulating material 15 and the side surface 13 of the outer plate 10 absorbs the outer box deformation factors such as unevenness and warpage of the surface of the vacuum heat insulating material 15 and reduces the deformation of the outer surface of the outer box. Can be prevented. Further, by arranging the intervening member 33 on the side surface 13 side of the outer plate 10 in advance, it is possible to increase the production efficiency in the assembly process.
[0068]
Further, since the intervening member 33 is a soft member softer than the vacuum heat insulating material 15, the soft member absorbs an outer box deformation factor such as unevenness and warpage of the surface of the vacuum heat insulating material 15, and deforms the outer surface of the outer box. It can be reliably prevented.
[0069]
In addition, as shown in FIG. 12, after the interposition member 34 for preventing deformation of the outer surface of the outer box is previously arranged on the vacuum heat insulator 15, the vacuum heat insulator 15 may be attached to the outer box. In this case, the intervening member between the vacuum heat insulating material and the outer case absorbs irregularities of the surface of the vacuum heat insulating material, deformation factors of the outer case such as warpage, and can prevent deformation of the outer surface of the outer case. By providing the vacuum heat insulating material 15 in advance, the production efficiency in the assembly process can be increased.
[0070]
Further, the intervening member 34 may be a hard member harder than the vacuum heat insulating material 15. In this case, it is possible to prevent factors such as unevenness and warpage of the surface of the vacuum heat insulating material 15 from being transmitted to the outer surface of the outer case, and to prevent deformation of the outer surface of the outer case.
[0071]
(Embodiment 3)
FIG. 13 is a schematic diagram showing an inspection process in the refrigerator according to Embodiment 3 of the present invention. Detailed description of the same parts as those in the first or second embodiment will be omitted, and only different parts will be described.
[0072]
In the figure, reference numeral 35 denotes a vacuum insulating material incorporated in the outer box by the method for manufacturing a heat insulating box of the first or second embodiment, and thereafter, a rigid urethane foam is foamed between the outer box and the inner box. Refrigerator incorporating refrigeration cycle components such as a condenser, a decompression device, and an evaporator. Reference numeral 36 denotes a sounding device, which is used in an inspection process for inspecting whether or not the vacuum heat insulating material maintains a predetermined heat insulating performance at a predetermined position after hard urethane foam is foamed. Specifically, the sound insulation device 36 is applied to the outer surface of the outer box in which the vacuum heat insulating materials 15, 16, 17 are attached to the outer plate 10 so that the vacuum heat insulating materials 15, 16, 17 are hardened before the rigid urethane foam is foamed. The difference in sound quality at the time of tapping between the case where the sound is not at the regular position and the case where the sound is at the regular position due to falling off from the attachment surface is discriminated to determine the presence or absence. Also, even if the vacuum insulation materials 15, 16, 17 are broken or broken or the like, the degree of vacuum quality is poor (insulation performance is poor) even if the vacuum insulation materials 15, 16 and 17 are arranged at regular positions, the difference in sound quality at the time of tapping can be distinguished. You can make a decision.
[0073]
It should be noted that the hammering test is not limited to the outer plate 10, but is preferably performed at a location where the vacuum heat insulating material is attached.
[0074]
In addition, the refrigerator 35 is configured such that one flat plate 10 is bent to form a side surface and a top surface of the outer box, and the vacuum heat insulating materials 15, 16, and 17 are attached to the outer box after bending the flat plate, A foam made of rigid urethane foam between the inner boxes, and then incorporating refrigeration cycle parts such as compressors, condensers, decompression devices, evaporators, etc. By using a box, a refrigerator with low power consumption can be provided.
[0075]
(Embodiment 4)
FIG. 14 is a schematic diagram showing an inspection process in the refrigerator according to the fourth embodiment of the present invention. Detailed description of the same parts as those in the first or second embodiment will be omitted, and only different parts will be described.
[0076]
In the figure, reference numeral 37 denotes a vacuum heat insulating material incorporated in an outer box by the method for manufacturing a heat insulating box of the first or second embodiment, and thereafter, a rigid urethane foam is foamed between the outer box and the inner box. Refrigerator incorporating refrigeration cycle components such as a condenser, a decompression device, and an evaporator. Numeral 38 is a thermography device capable of measuring the surface temperature in a non-contact manner using infrared rays. The thermographic device 38 is installed in a room 39 in which the inside is kept at a constant temperature. Is used in an inspection process for inspecting whether or not is maintained. Specifically, while operating the refrigerator, the camera of the thermography device is aligned with the outer surface of the outer box in which the vacuum insulating materials 15, 16 and 17 are attached to the outer plate 10, and the vacuum heat insulating is performed based on the image data (temperature distribution). Inspection of the disposition of the materials 15, 16, 17 is inspected. For example, in the case of irregularity, the heat insulation performance is reduced, and the surface temperature is reduced.
Therefore, it is possible to easily and reliably arrange the vacuum heat insulating materials 15, 16, 17 or inspect the defective state without contacting the refrigerator body.
[0077]
【The invention's effect】
As described above, the invention according to claim 1 is characterized in that, in the production of a heat insulating box provided with a rigid urethane foam and a vacuum heat insulating material between an outer box and an inner box, one flat plate is bent to form the outer box. A bending step of forming the side and top surfaces, and after the bending step, using an outer jig and an inner jig, sandwiching the inner and outer surfaces between two planes, and attaching a vacuum insulating material to the inner surface of the outer box And a step of filling and foaming the rigid urethane foam in a space having the vacuum heat insulating material formed by engaging the inner box with the outer box. Thus, the installation efficiency of the work space in the manufacturing process can be improved. Further, there is no problem that the vacuum heat insulating material is peeled off by the impact at the time of bending. In addition, irregular work is eliminated, and damage to the vacuum heat insulating material by the operator can be prevented. In addition, the positioning of the position where the vacuum heat insulating material is to be attached is ensured by the jig, and the variation in attachment can be suppressed. Further, a plurality of vacuum heat insulating materials can be attached to a plurality of surfaces at one time, so that the production efficiency of the manufacturing process can be improved. Further, by sandwiching the attaching portion of the outer box between two planes from the inside and the outside, the pressing pressure can be made uniform at the time of attaching the vacuum heat insulating material, and deformation of the outer surface of the outer surface of the vacuum heat insulating material bonding surface can be prevented.
[0078]
According to a second aspect of the present invention, in the first aspect, the inner jig supports two ends of the vacuum heat insulating material with an L-shaped support portion. Is reliably supported by the inner jig, and the work of supporting the inner jig is facilitated, so that the production efficiency of the manufacturing process can be increased.
[0079]
According to a third aspect of the present invention, in the first or second aspect of the invention, the inner jig has the vacuum heat insulating material supporting surface press-fitted sequentially from one direction to the bonding surface of the outer box. Therefore, an air layer is not generated between the vacuum heat insulating material and the outer box, and the outer box external deformation of the vacuum heat insulating material bonding surface can be prevented.
[0080]
Further, the invention according to claim 4 of the present invention is directed to a method of manufacturing a heat insulating box having a rigid urethane foam and a vacuum heat insulating material between an outer box and an inner box, wherein one flat plate is bent to form the outer box. And a step of attaching a vacuum heat insulating material to the outer box, and a step of attaching a vacuum heat insulating material to the outer box. In the vacuum heat insulating material attaching step, the outer surface of the outer box is deformed by the vacuum heat insulating material. After arranging the intervening member in advance to prevent the interposition member, the intervening member side is attached to the outer box. The deformation of the outer surface of the outer box can be prevented by absorbing the box deformation factor. In addition, by providing the intervening member on the vacuum heat insulating material in advance, the production efficiency in the assembly process can be increased.
[0081]
The invention according to claim 5 of the present invention is directed to a method of manufacturing a heat insulating box having a rigid urethane foam and a vacuum heat insulating material between an outer box and an inner box. And a step of attaching a vacuum heat insulating material to the outer box, and a step of attaching a vacuum heat insulating material to the outer box. In the vacuum heat insulating material attaching step, the outer box side is deformed on the outer box side. The vacuum heat insulating material is attached to the outer box after the intervening member for preventing the heat insulation is provided in advance. The deformation of the outer surface of the outer box can be prevented by absorbing the box deformation factor. Further, by arranging the intervening member on the outer box side in advance, it is possible to increase the production efficiency in the assembling process.
[0082]
The invention according to claim 6 of the present invention is the invention according to claim 4 or 5, wherein the interposed member is a soft member softer than the vacuum heat insulating material, and the unevenness of the surface of the vacuum heat insulating material is improved. The soft member absorbs a deformation factor of the outer box such as a warp, so that deformation of the outer surface of the outer box can be reliably prevented.
[0083]
Further, the invention according to claim 7 of the present invention is the invention according to claim 4 or 5, wherein the interposed member is a hard member harder than the vacuum heat insulating material, and the unevenness of the surface of the vacuum heat insulating material, An outer box deformation factor such as a warp can be prevented from being transmitted to the outer box outer surface, and deformation of the outer box outer surface can be prevented.
[0084]
The invention according to claim 8 of the present invention is the invention according to any one of claims 1 to 7, wherein the adhesive member between the vacuum heat insulating material and the outer box is attached to the vacuum heat insulating material side. The deformation of the outer surface of the outer case can be prevented by absorbing the deformation factors of the outer case such as unevenness and warpage on the surface of the vacuum heat insulating material by the thickness of the adhesive member. Further, by providing the adhesive member on the vacuum heat insulating material side, the adhesive member can be used efficiently.
[0085]
According to a ninth aspect of the present invention, in the invention according to the eighth aspect, the adhesive member is applied to the entire surface of the vacuum heat insulating material. An air layer is not generated between the outer case and the outer case, so that the outer surface of the outer surface of the vacuum heat insulating material can be prevented from deforming.
[0086]
According to a tenth aspect of the present invention, in the ninth aspect of the present invention, the adhesive member applied to the vacuum heat insulating material is formed by attaching the adhesive member to one of the oppositely rotating rollers. This is performed through a vacuum heat insulating material in between, so that the adhesive member can be uniformly applied to the vacuum heat insulating material without excess or shortage. Further, the efficiency of the coating operation can be improved.
[0087]
The invention according to claim 11 of the present invention is the invention according to claim 9 or 10, wherein the adhesive member is a gel-like hot melt, and the gel-like hot melt is a surface of the vacuum heat insulating material. The deformation of the outer surface of the outer box can be prevented by absorbing outer box deformation factors such as unevenness and warpage of the outer box.
[0088]
According to a twelfth aspect of the present invention, in the invention according to any one of the ninth to eleventh aspects, the adhesive member is a gel-like curable adhesive. The subsequent vacuum insulation material is not displaced or peeled off, and the bonding reliability is improved.
[0089]
Further, the invention according to claim 13 of the present invention is characterized in that, in a heat insulating box provided with a hard urethane foam and a vacuum heat insulating material between an outer box and an inner box, after the completion of the hard urethane foam foaming, the vacuum heat insulating material is An inspection step is performed for inspecting whether or not a predetermined heat insulation performance is maintained at a predetermined position. A defect of the heat insulation box can be found in advance, and shipment of a defective product can be prevented.
[0090]
According to a fourteenth aspect of the present invention, in the thirteenth aspect, the inspection step is performed by an auditory sound by a tapping sound, and the vacuum heat insulating material is arranged at a predetermined position. Can be easily checked.
[0091]
According to a fifteenth aspect of the present invention, in the invention according to the thirteenth aspect, the inspection step is an inspection at a surface temperature using a thermography device. It can be easily confirmed in a non-contact manner by visually judging the surface temperature of the outer case using a thermography device to determine whether or not the heat insulation performance is maintained.
[0092]
According to a sixteenth aspect of the present invention, a refrigerator using an insulated box manufactured by the method for manufacturing an insulated box according to any one of the first to fifteenth aspects is provided. It is possible to provide a refrigerator with low power consumption and a refrigerator with a reduced heat insulation wall thickness and improved internal volume efficiency with respect to the external volume.
[Brief description of the drawings]
FIG. 1 is a perspective view showing a state before folding an outer box of a heat insulating box of a refrigerator according to Embodiment 1 of the present invention.
FIG. 2 is an exemplary perspective view showing a state after the outer box of the heat insulating box of the refrigerator according to the embodiment is bent;
FIG. 3 is an exemplary perspective view showing a state after the outer box of the heat insulating box of the refrigerator according to the embodiment is bent;
FIG. 4 is a process diagram showing a manufacturing process of the heat insulating box of the refrigerator according to the embodiment.
FIG. 5 is a plan view showing a jig for attaching a vacuum heat insulating material to an outer box of the heat insulating box of the refrigerator according to the embodiment;
FIG. 6 is a perspective view of a main part of a jig for attaching a vacuum heat insulating material to an outer box of the heat insulating box of the refrigerator according to the embodiment;
FIG. 7 is a schematic view showing an apparatus for applying an adhesive member to a vacuum heat insulating material used in the refrigerator of the embodiment.
FIG. 8 is a schematic diagram showing an apparatus for applying an adhesive member to a vacuum heat insulating material used in the refrigerator of the embodiment.
FIG. 9 is an essential part plan view showing a step of attaching a vacuum heat insulating material to an outer box of the heat insulating box of the refrigerator of the embodiment;
FIG. 10 is an essential part plan view showing a step of attaching a vacuum heat insulating material to the outer box of the heat insulating box of the refrigerator of the embodiment;
FIG. 11 is a schematic diagram of a method for manufacturing a heat insulating box according to the second embodiment of the present invention.
FIG. 12 is a schematic diagram of a method for manufacturing a heat insulating box according to the second embodiment of the present invention.
FIG. 13 is a schematic view showing an inspection process in the refrigerator according to the third embodiment of the present invention.
FIG. 14 is a schematic diagram showing an inspection process in the refrigerator according to the fourth embodiment of the present invention.
FIG. 15 is a perspective view showing a state before bending an outer box of a heat insulating box of a conventional refrigerator.
FIG. 16 is a perspective view showing a state where a vacuum heat insulating material is attached to an outer box of the heat insulating box of the refrigerator.
FIG. 17 is a perspective view showing a state after the outer box of the heat insulating box of the refrigerator is bent.
FIG. 18 is a process diagram showing a bending process of the heat insulating box of the refrigerator.
[Explanation of symbols]
10 Outside plate
13 sides
14 Top
15,16,17 Vacuum insulation
18 Vacuum insulation sticking jig
19 Outside jig
20 Inner jig
21, 22 Side jig
23 Top Jig
26 L-shaped support
27 Upper roller
28 Lower roller
32 adhesive members
33, 34 Interposed member
35, 37 Refrigerator
36 sounding device
38 Thermography equipment

Claims

A step of bending a single flat plate to form a side surface and a top surface of the outer box in the manufacture of an insulating box body including a rigid urethane foam and a vacuum heat insulating material between the outer box and the inner box; After the process, using an outer jig and an inner jig, a vacuum insulating material attaching step of sandwiching between two inner and outer flat surfaces and attaching a vacuum insulating material to the inner surface of the outer box, and engaging the inner box with the outer box And filling the rigid urethane foam into a space having the vacuum heat insulating material formed as described above.

The method according to claim 1, wherein the inner jig supports two ends of the vacuum heat insulating material with an L-shaped support.

The method for manufacturing a heat insulating box according to claim 1 or 2, wherein the inner jig has a vacuum heat insulating material supporting surface pressed in sequence from one direction to a surface to which the outer box is attached.

In the production of a heat insulating box provided with a rigid urethane foam and a vacuum heat insulating material between an outer box and an inner box, a bending step of bending a single flat plate to form the side and top surfaces of the outer box; A vacuum insulating material attaching step of attaching the material to the outer box. In the vacuum insulating material attaching step, an intervening member that prevents deformation of the outer surface of the outer box is provided in advance in the vacuum insulating material, A method for manufacturing a heat-insulated box, comprising attaching the side to an outer box.

In the production of a heat insulating box provided with a rigid urethane foam and a vacuum heat insulating material between an outer box and an inner box, a bending step of bending a single flat plate to form the side and top surfaces of the outer box; A vacuum insulating material attaching step of attaching the material to the outer box. In the vacuum insulating material attaching step, after an intervening member for preventing deformation of the outer surface of the outer box is disposed on the outer box side in advance, the vacuum insulating material is attached. A method for manufacturing a heat-insulating box, comprising attaching a material to an outer box.

The method according to claim 4, wherein the interposed member is a soft member that is softer than the vacuum heat insulating material.

The method according to claim 4 or 5, wherein the interposed member is a hard member that is harder than the vacuum heat insulating material.

The method for manufacturing a heat insulating box according to any one of claims 1 to 7, wherein the adhesive member between the vacuum heat insulating material and the outer box is provided on the vacuum heat insulating material side.

9. The method according to claim 8, wherein the adhesive member is applied to the entire surface of the vacuum heat insulating material.

The manufacturing method of a heat insulating box according to claim 9, wherein the bonding member applied to the vacuum heat insulating material is formed by attaching the bonding member to one of the rollers rotating opposite to each other and passing the vacuum heat insulating material between the rollers. Method.

The method according to claim 9 or 10, wherein the adhesive member is a gel-like hot melt.

The method according to any one of claims 9 to 11, wherein the adhesive member is a gel-type curable adhesive.

In the production of a heat insulating box provided with a hard urethane foam and a vacuum heat insulating material between the outer case and the inner case, after completion of the foaming of the hard urethane foam, the vacuum heat insulating material maintains a predetermined heat insulating performance at a predetermined position. A method for manufacturing a heat-insulated box, comprising performing an inspection step of inspecting whether or not the heat insulation box is present.

The method for manufacturing a heat insulating box according to claim 13, wherein the inspection step is an inspection based on a listening sound by a tapping sound.

14. The method for manufacturing a heat insulating box according to claim 13, wherein the inspection step is an inspection at a surface temperature using a thermography device.

A refrigerator using the heat-insulating box manufactured by the method for manufacturing a heat-insulating box according to any one of claims 1 to 15.