JP2020159569A - Heat insulating door and refrigerator - Google Patents

Abstract

To provide a heat insulating door that has a heat insulating layer filled with a foamed heat insulating material evenly, and in which degradation in appearance is suppressed.SOLUTION: A refrigerator door (heat insulating door) 11 of a refrigerator 1 comprises a front member (front surface side member) 21 and a door back (rear surface side member) 22 arranged opposite to the front member 21. Between the front member 21 and the door back 22, a heat insulating layer 23 having a foamed heat insulating material is provided. Further, in a region where the heat insulating layer 22 is formed, a mesh sheet (mesh sheet member) 24 is arranged on the back surface of the front member 21. Concavities and convexities (convex parts 24a and concave parts 24b) are formed on the surface of the mesh sheet 24 facing the back surface of the front member 21.SELECTED DRAWING: Figure 2

Description

The present invention relates to a heat insulating door. The present invention also relates to a refrigerator provided with this heat insulating door.

Generally, the refrigerator is provided with a heat insulating box so as to cover the outer periphery of the storage space in order to insulate the refrigerator from the surroundings. The refrigerator door also has heat insulating properties.

A heat insulating layer is formed inside the door having such heat insulating properties. The heat insulating layer is formed of a foamed heat insulating material such as polyurethane foam (also referred to as rigid urethane foam) in order to maintain the heat insulating performance in the refrigerator. That is, the heat insulating door is mainly composed of an outer plate (also referred to as a front side member) constituting the outer shape of the door, an inner plate (also referred to as a back side member), and the above-mentioned heat insulating layer existing between them. Has been done.

When manufacturing a heat insulating door having such a structure, for example, the foamed heat insulating material is injected by an open injection method as disclosed in Patent Document 1. The open injection method is an upper surface plate (also called a back side member) when injecting a foamed heat insulating material (resin liquid) into a space formed by a lower surface plate (also called a front side member) and an outer peripheral frame. This is a method in which the resin liquid is injected into the open space by opening the open space and placing the upper portion open. By adopting this open injection method, it is not necessary to provide an injection hole in the upper surface plate, and injection can be performed while moving the injection head. Therefore, the resin liquid can be uniformly injected all around the space in a short time, and a heat insulating door having a uniform heat insulating layer can be manufactured.

Japanese Unexamined Patent Publication No. 10-86160

By the way, a protective layer may be formed on the back surface of the lower surface plate on which the foamed heat insulating material is dropped for the convenience of production. Due to the compatibility between this protective layer and the foamed heat insulating material, the film thickness of the protective layer formed on the surface, and the variation in the flatness of the back surface of the lower surface plate, the dropped foamed heat insulating material spreads uniformly. It may not be. If the dropped foamed heat insulating material does not spread uniformly on the back surface of the lower surface plate, uneven filling may occur when the heat insulating material foams and is filled in the door. If there is a corner of the lower surface plate where the foamed heat insulating material cannot be filled, a cavity is formed in the corner, which causes unevenness on the surface of the heat insulating door. This can reduce the appearance quality of the door.

Therefore, in one aspect of the present invention, there is provided a heat insulating door having a heat insulating layer in which the foamed heat insulating material is more uniformly filled, and the deterioration of the appearance quality is suppressed.

The heat insulating door according to one aspect of the present invention is located between the front side member, the back side member arranged to face the front side member, and the front side member and the back side member, and is a foamed heat insulating material. It is provided with a heat insulating layer having the above, and a mesh-like sheet member arranged on the back surface of the front surface side member and having irregularities on the back surface.

In the heat insulating door of one aspect of the present invention, at least a part of the mesh-like sheet member may be adhered to the back surface of the front surface side member.

In the heat insulating door of one aspect of the present invention, the adhesive portion of the front side member of the mesh sheet member with the back surface may be obtained by curing the resin material.

In the heat insulating door of one aspect of the present invention, the mesh-like sheet member may be formed by weaving a plurality of linear bodies.

In the heat insulating door of one aspect of the present invention, the mesh-like sheet member may be obtained by at least partially curing the resin material.

In the heat insulating door of one aspect of the present invention, the mesh-like sheet member may be adhered to the back surface of the front surface side member by irradiating the electron beam.

In the heat insulating door of one aspect of the present invention, the heat insulating layer is formed by dropping a foamed heat insulating material from an injection head that moves along the longitudinal direction of the front surface member, and is formed by dropping the foam heat insulating material. The shape sheet member may have a mesh shape in which the longitudinal direction of the front surface side member is shorter than the direction orthogonal to the longitudinal direction.

Another aspect of the present invention relates to a refrigerator provided with a heat insulating door. Here, the heat insulating door is a heat insulating door according to one aspect of the present invention described above.

In the heat insulating door according to one aspect of the present invention, a mesh-like sheet member is arranged on the back surface of the front side member. Thereby, when the heat insulating material is dropped on the back surface of the front side member, the heat insulating material can be uniformly spread. Therefore, it is possible to obtain a heat insulating door in which the heat insulating material has a heat insulating layer more uniformly filled and the deterioration of the appearance quality is suppressed.

Further, the surface of the mesh-like sheet member is formed with irregularities at least on the side facing the front surface side member. As a result, the front surface of the mesh-like sheet member has a portion that contacts the back surface of the front surface side member and a portion that does not contact the back surface of the front surface side member. Therefore, the heat insulating material can be distributed even in the gap formed between the mesh-like sheet member and the front side member.

Further, the refrigerator according to one aspect of the present invention has a good appearance because it is provided with the heat insulating door as described above.

It is a perspective view which shows the appearance of the refrigerator which concerns on one Embodiment of this invention. It is sectional drawing which shows the internal structure of the refrigerating room door provided in the refrigerator shown in FIG. It is a schematic diagram which shows the outline of the manufacturing method of the refrigerating room door which concerns on one Embodiment of this invention. It is a schematic diagram which shows the back surface of the front member of the refrigerator which concerns on 1st Embodiment. It is a schematic diagram which shows the part of the net-like sheet shown in FIG. 4 enlarged. It is sectional drawing which shows the part of the net-like sheet shown in FIG. 4 enlarged. It is a schematic diagram which shows the adhesion position of a net-like sheet and a front member. It is a schematic diagram which shows another example of the adhesion position of a net-like sheet and a front member. It is a schematic diagram which shows the back surface of the front member of the refrigerator which concerns on 2nd Embodiment. It is a schematic diagram which shows the back surface of the front member of the refrigerator which concerns on 3rd Embodiment. It is a schematic diagram which shows the back surface of the front member of the refrigerator which concerns on 4th Embodiment.

Hereinafter, embodiments of the present invention will be described with reference to the drawings. In the following description, the same parts are designated by the same reference numerals. Their names and functions are the same. Therefore, the detailed description of them will not be repeated.

[First Embodiment]
(Overall configuration of refrigerator)
In the present embodiment, a refrigerator 1 having two storage chambers (refrigerator chamber 2 and freezer compartment 3) will be described as an example. FIG. 1 shows the appearance of the refrigerator 1 according to the present embodiment. FIG. 1 shows the appearance of the refrigerator 1 in a state where each door is opened. The refrigerator 1 is mainly composed of a main body 10, a refrigerating room door 11, and a freezing room door 12. The refrigerating room door 11 and the freezing room door 12 are heat insulating doors of an example of the present invention. The outer shape of the main body 10 is formed by a heat insulating box.

A refrigerating room 2 is arranged in the upper part of the refrigerator 1. A refrigerating room door 11 is attached to the opening on the front surface of the refrigerating room 2. A freezing room 3 is arranged in the lower part of the refrigerator 1. A freezing room door 12 is attached to the opening on the front surface of the freezing room 3.

The configuration and arrangement of each storage room in the refrigerator 1 is not limited to the above. The configuration and arrangement of each storage room can be appropriately changed according to the capacity and use of the refrigerator.

In the present embodiment, the surface on which the door is provided is the front surface (front surface) of the refrigerator 1. Then, with reference to the front surface, each surface of the main body 10 of the refrigerator 1 is defined as an upper surface, a side surface, a back surface, and a bottom surface based on the positions existing when the refrigerator 1 is installed in a normal state. Further, when the refrigerator 1 is viewed from the front side, the side located above is called the upper side of the refrigerator 1 (or the refrigerator door 11), and the side located below is referred to as the refrigerator 1 (or the refrigerator door 11). Called the lower side. Further, when the refrigerator 1 is viewed from the front side, the side located on the left is called the left side of the refrigerator 1 (or the refrigerator door 11), and the side located on the right is the right side of the refrigerator 1 (or the refrigerator door 11). Called.

(Composition of refrigerator door)
Subsequently, the internal configuration of the refrigerator compartment door 11 will be described with reference to the drawings. FIG. 2 shows a cross-sectional configuration of the refrigerator compartment door 11.

The refrigerating room door 11 is mainly composed of a front member (front side member) 21, a door back (rear side member) 22, a heat insulating layer 23, a mesh sheet (mesh sheet member) 24, and the like.

The front member 21 is located on the front side of the refrigerator compartment door 11 and constitutes the front surface of the main body portion of the refrigerator compartment door 11. The door back 22 is arranged to face the front member 21 and constitutes the back side of the refrigerator compartment door 11. By attaching the door back 22 to the back surface of the front member 21, the outer shape of the main body portion of the refrigerator compartment door 11 is formed. The heat insulating layer 23 is located between the front member 21 and the door back 22.

The heat insulating layer 23 is made of, for example, a foamed heat insulating material. The foamed heat insulating material includes, for example, polyurethane foam (also referred to as rigid urethane foam). The foamed heat insulating material is formed by dropping a liquid heat insulating material 40 onto the back surface of the front member 21 (see FIG. 3) and foaming the heat insulating material 40 in the space between the front member 21 and the door back 22. Will be done. Insulation materials for polyurethane foam include polyisocyanates, polyols, foaming agents, plasticizers and the like.

The heat insulating layer 23 may include a vacuum heat insulating material. The vacuum heat insulating material is a sheet-shaped or plate-shaped heat insulating material. It is desirable to place the vacuum heat insulating material in a refrigerator where particularly high heat insulating properties are required. Since the heat insulating layer 23 contains the vacuum heat insulating material, the heat insulating performance of the refrigerating room door 11 can be further improved.

The mesh sheet 24 is arranged between the front member 21 and the door back 22. Specifically, the net-like sheet 24 is arranged on the back surface of the front member 21. As will be described later, when the refrigerating chamber door 11 is manufactured, the mesh sheet 24 is arranged on the back surface of the front member 21. In this state, the heat insulating material is dropped onto the front member 21. After that, the door back 22 is mounted on the front member 21, and the heat insulating layer 23 including the foamed heat insulating material is formed in the space between the front member 21 and the door back 22 in a state where the mesh sheet 24 is arranged. As a result, the net-like sheet 24 is located between the front member 21 and the heat insulating layer 23.

The freezing room door 12 also has the same internal structure as the refrigerating room door 11.

(Manufacturing method of refrigerator door)
Subsequently, a method of manufacturing the refrigerator compartment door 11 will be described. The method for manufacturing the refrigerator compartment door 11 according to the present embodiment includes a dropping step of dropping the heat insulating material on the front surface (back surface) of the front member 21, and an attachment step of attaching the door back 22 on the front member 21 after dropping the heat insulating material. And at least a foaming step of foaming the heat insulating material in the space between the front member 21 and the door back 22.

FIG. 3 shows how the dropping step is performed in the manufacturing method of the refrigerating chamber door 11 according to the present embodiment in the order of steps (1) to (4). Note that FIG. 3 shows, as a comparative example, a conventional manufacturing method, that is, a state in which the dropping step is performed without arranging the net-like sheet 24 on the front member 21.

In the stage before the dropping step, the net-like sheet 24 is arranged on the front member 21. The front member 21 in this state is installed below the heat insulating material injection device 50. The injection device 50 has an injection head 51 extending downward. The injection head 51 drops the heat insulating material 40 while moving in one direction (in the example shown in FIG. 3, moving to the right as shown by the arrow). The moving direction of the injection head 51 is preferably a direction along the longitudinal direction of the front member 21 (in the present embodiment, the vertical direction of the refrigerating chamber door 11). This makes it easier to ensure the uniformity of the heat insulating material 40 in the longitudinal direction over a longer distance.

In the present embodiment, since the mesh sheet 24 is arranged on the front member 21, the dropped heat insulating material 40 spreads vertically and horizontally along the mesh shape of the mesh sheet 24. The net-like sheet 24 is placed on the back surface of the front member 21. The net-like sheet 24 is adhered to the back surface of the front member 21. At this time, the entire surface of the mesh sheet 24 facing the back surface of the front member 21 is not entirely adhered to the front member 21, and at least a part of the mesh sheet 24 (for example, (for example, the back surface of the front member 21). (Some of the convex portions 24a (see FIG. 2)) located on the side facing the front member 21 are adhered to the back surface of the front member 21.

On the other hand, in the comparative example, since the net-like sheet 24 is not arranged on the front member 21, the heat insulating material 40 is difficult to spread.

When the injection head 51 reaches the end position (end point B) of the dropping, the injection device 50 finishes dropping the heat insulating material 40, and then the injection head 51 moves away from the front member 21 ((3) in FIG. 3 and (See (4)).

In the mounting step after the dropping step, the door back 22 is mounted so as to cover the front member 21. As a result, the outer shape of the refrigerator compartment door 11 having a space inside is formed.

In the foaming process, the heat insulating material 40 reacts in the internal space of the refrigerating chamber door 11 to generate gas. As a result, a foamed heat insulating material (specifically, polyurethane foam) is formed in the internal space of the refrigerator compartment door 11. Finally, the foamed heat insulating material is cured to obtain a heat insulating layer 23 having a hard foamed heat insulating material.

As described above, in the present embodiment, the heat insulating material 40 is injected into the inside of the refrigerator compartment door 11 by using the open injection method, and the heat insulating layer 23 is formed. The heat insulating material injection device 50 shown in FIG. 3 is an example, and the injection device used in the method for manufacturing the refrigerating chamber door 11 according to the present embodiment is not limited to this.

In the present embodiment, the dropping step is carried out with the net-like sheet 24 arranged on the front member 21, so that the heat insulating material 40 flows more smoothly in the horizontal direction to insulate a wider area of the front member 21. The material 40 can be expanded.

Further, in the present embodiment, at least a part of the net-like sheet 24 is adhered to the back surface of the front member 21. That is, at least a part of the net-like sheet 24 is fixed on the back surface of the front member 21. As a result, it is possible to prevent the net-like sheet 24 from moving or bending in the dropping step of the heat insulating material 40. In addition, the heat insulating member 40 that has entered under the mesh and expanded due to foaming during the dropping process can prevent the mesh sheet 24 from floating. Therefore, the fluidity of the heat insulating material by the net-like sheet 24 can be maintained over the dropping process, and the heat insulating material 40 can be extended to a wider area of the front member 21.

On the other hand, even in the conventional example in which the mesh sheet 24 is not arranged, by controlling the moving position, the speed, and the dropping amount of the injection head 51, the moving direction of the injection head 51 is set to the longitudinal direction of the front member 21. On the other hand, the heat insulating material 40 can be dropped uniformly to some extent. On the other hand, the heat insulating material 40 is difficult to spread because the dropping of the front member 21 cannot be controlled by the movement of the injection head 51 in the lateral direction of the front member 21 orthogonal to the moving direction of the injection head 51. Therefore, in the vicinity of the left and right side ends of the front member 21, the filling degree of the heat insulating material 40 is lower than that in the central portion, and the filling degree of the heat insulating material 40 may become non-uniform. When the foaming process is performed in such a state, a cavity is formed between the heat insulating material 40 and the front member 21 at a place where the heat insulating material 40 is insufficiently filled, and the adhesiveness with the front member 21 is lowered. Unevenness is generated on the front surface portion, and the appearance of the refrigerator 1 is spoiled.

The back surface of the front member 21 formed of a metal plate-shaped member such as a steel plate may be coated with a coating agent as a protective layer against scratches and chemical changes. The heat insulating material dropped on the front member 21 may be more difficult to spread due to the influence of the compatibility between the coating agent and the heat insulating material and the variation in the film thickness of the coating agent. For example, when a coating agent having high adhesiveness to the heat insulating material 40 is applied to the surface of the front member 21, the adhesive force between the front member 21 and the heat insulating material (polyurethane foam material) is increased, and the fluidity of the heat insulating material is increased. May be more hindered.

Therefore, by arranging the mesh sheet 24 on the back surface of the front member 21 as in the present embodiment, the direct contact between the front surface of the front member 21 and the heat insulating material 40 is suppressed, and the fluidity of the heat insulating material 40 is reduced. It can be improved and the heat insulating material 40 can be uniformly spread on the front member 21. The net-like sheet 24 preferably has non-adhesiveness to the heat insulating material 40 and the foamed heat insulating material formed from the heat insulating material 40. As a result, the heat insulating material 40 can be spread more uniformly on the front member 21.

Further, in the present embodiment, the net-like sheet 24 is the start position of dropping the heat insulating material 40 dropped from the injection head 51 (position A in the plan view of FIG. 3 (4)) and the outside thereof, and the end of dropping. It is arranged over the entire area including the position (position B in the plan view of FIG. 3 (4)) and its outside. As a result, the heat insulating material 40 can be more reliably extended to the region outside the region from the start point A to the end point B of the dropping of the heat insulating material 40.

The net-like sheet 24 is preferably made of a resin material such as polypropylene (PP), polyethylene (PE), polyester, polyamide, silicon-based resin, and fluorine-based resin. These resin materials have non-adhesiveness to polyurethane. Therefore, when the heat insulating layer 23 has polyurethane foam, the fluidity and expandability of the heat insulating material 40 at the time of forming the heat insulating layer can be enhanced.

FIG. 2 shows an enlarged part of the net-like sheet 24 and the front member 21. As shown in FIG. 2, the net-like sheet 24 has irregularities on its surface. Specifically, the net-like sheet 24 has a portion (convex portion 24a) protruding toward the back surface of the front member 21 and a portion (concave portion 24b) recessed with respect to the back surface of the front member 21. There is. In addition, such unevenness may be formed on both sides of the net-like sheet 24, or may be formed only on the surface facing the back surface of the front member 21.

The convex portion 24a of the net-like sheet 24 formed on the side facing the front member 21 is in contact with the back surface of the front member 21. At least some of these plurality of convex portions 24a are adhered to the back surface of the front member 21. In the enlarged view of FIG. 2, the adhesive portion 31 is surrounded by a broken line frame. As a result, the net-like sheet 24 is fixed on the back surface of the front member 21.

FIG. 4 shows a more specific configuration of the net-like sheet 24 arranged on the front member 21. In FIG. 4, the moving direction of the injection head 51 in the dropping step is indicated by an arrow. Further, in FIG. 4, the mesh shape of the mesh sheet 24 is enlarged and shown.

As shown in FIG. 4, the net-like sheet 24 is formed of a plurality of fibers (linear bodies) extending vertically and horizontally. The mesh sheet 24 has a grid-like mesh shape with rectangular openings. Here, the mesh shape of the mesh sheet 24 is a rectangular shape in which the moving direction of the injection head 51 is shorter than the direction orthogonal to the moving direction. That is, in the rectangular opening of the net-like sheet 24, the length L1 in the moving direction of the injection head 51 is smaller than the length L2 in the direction orthogonal to the moving direction.

If the length of the mesh is long, that is, if the mesh is coarse, the liquid heat insulating material 40 tends to flow on the mesh. However, on the other hand, if the mesh is coarse, the liquid heat insulating material 40 easily falls on the surface of the front member 21 from between the meshes. On the contrary, if the length of the mesh is short, the liquid heat insulating material 40 is hard to fall from between the meshes, but the fluidity on the mesh is also reduced.

Therefore, in the present embodiment, since the mesh shape of the mesh sheet 24 has the above-mentioned structure, the dropped heat insulating material 40 is in the longitudinal direction (direction of length L2) of the mesh (opening). The flow to is promoted. As a result, the heat insulating material 40 can be further expanded in a direction orthogonal to the moving direction of the injection head 51 (that is, in the left-right direction of the refrigerating chamber door 11). On the other hand, in the lateral direction (direction of length L1) of the mesh (opening), the mesh can be made dense, so that the liquid heat insulating material 40 is prevented from falling from between the meshes. Therefore, the liquid heat insulating material 40 can be more reliably flowed in the longitudinal direction of the mesh (direction of length L2).

In the mesh sheet 24 having such a mesh shape, the opening ratio of the openings formed in the sheet is preferably 50% or more and 97% or less. As a result, the dropped heat insulating material 40 can be passed through the upper surface of the mesh sheet 24 and flowed to the outside of the dropping region, and a part of the dropped heat insulating material 40 can be dropped on the surface of the front member 21 through the opening. .. Therefore, the heat insulating layer 23 made of the heat insulating material 40 can be uniformly formed between the mesh sheet 24 and the back surface of the front member 21, and it is possible to prevent the heat insulating material 40 and the back surface of the front member 21 from being separated from each other. Will be done.

The wire diameter of the fibers forming the net-like sheet 24 is preferably 0.2 mm or more, and more preferably 1.0 mm or more. By setting the wire diameter to 0.2 mm or more, the mesh sheet 24 can have a certain degree of rigidity and weight. Therefore, when the net-like sheet 24 is arranged on the front member 21, it is possible to prevent the net-like sheet 24 from being displaced. Further, by setting the wire diameter to 1.0 mm or more, a sufficient width for the liquid heat insulating material 40 to flow on the net can be secured, and the fluidity of the heat insulating material 40 on the net can be secured. improves.

If the wire diameter of the fibers forming the net-like sheet 24 is increased, the opening ratio of the opening of the net-like sheet 24 tends to decrease. In the present embodiment, as described above, the mesh densities in the longitudinal direction and the lateral direction of the mesh (opening) are changed. Therefore, by adjusting these densities, the opening ratio of the opening of the mesh sheet 24 is changed. Can be set to the desired ratio as described above.

In addition, two or more net-like sheets 24 may be arranged in a stack. At this time, by slightly shifting the mesh shape of each of the mesh sheets 24 and stacking them, the contact area between the heat insulating material 40 immediately after dropping and the surface of the front member 21 is further reduced (that is, the aperture ratio is made smaller). Can be done. Thereby, the fluidity of the heat insulating material 40 can be further improved. In this case, it is sufficient that at least a part of the lower mesh sheet 24 is adhered to the back surface of the front member 21.

The net-like sheet 24 may be formed by weaving a plurality of fibers (linear bodies). 5 and 6 show a net-like sheet 24 formed by weaving a plurality of fibers. FIG. 6 is a cross-sectional view of the net-like sheet 24 shown in FIG. 5, which is a view of the net-like sheet 24 when viewed from the weft 26a side.

In the examples shown in these figures, the fibers (warp threads) 25a, 25b, 25c extending in the first direction have fibers (weft threads) 26a, 26b extending vertically in the second direction orthogonal to the first direction. Arranged to undulate. In the net-like sheet 24 shown in FIGS. 5 and 6, the warp and weft threads are woven in a plain weave. However, the weaving method of the net-like sheet 24 is not limited to the plain weave, and may be other weaving methods such as twill weave, satin weave, entwined weave, and imitation weave.

The fibers constituting the reticulated sheet 24 are preferably formed of a resin material such as polypropylene (PP), polyethylene (PE), polyester, polyamide, silicon-based resin, and fluorine-based resin.

When the net-like sheet 24 is formed by intersecting a plurality of fibers extending in two different directions, as in the plain-woven net-like sheet 24 shown in FIG. 5, the convex portion 24a extends in the first direction. It is formed at the intersection of the fiber (warp) 25 and the fiber (weft) 26 extending in the second direction. In FIG. 5, a broken line circle is attached to the position where the convex portion 24a is formed.

(About the method of adhering the mesh sheet)
As described above, the net-like sheet 24 is adhesively fixed to the front member 21. Examples of the method of fixing the mesh sheet 24 to the front member 21 include a method of adhering the mesh sheet 24 to the back surface of the front member 21 using a conventionally known adhesive. As shown in FIG. 2, the adhesive portion 31 between the mesh sheet 24 and the front member 21 exists on all or some of the convex portions 24a of the mesh sheet 24.

FIG. 7 shows the position of the adhesive portion 31 between the mesh sheet 24 and the front member 21. In the example shown in FIG. 7, among the intersections of the warp 25 and the weft 26, the intersections located at every other interval for both the warp 25 and the weft 26 are the adhesive portions 31. Further, FIG. 8 shows another example of the arrangement of the adhesive portion 31. In the example shown in FIG. 8, the number of the adhesive portions 31 is smaller than that in the example shown in FIG. 7, and the arrangement interval of each adhesive portion 31 is wider than that in the example shown in FIG. When the net-like sheet 24 is divided into a plurality of sheets, it is preferable to provide at least one adhesive portion 31 for each sheet.

Further, as another method of fixing the net-like sheet 24 to the front member 21, the net-like sheet 24 is formed of a resin material having curing properties such as electron beam curability, ultraviolet curability, or thermosetting, and these resin materials. It is also possible to cure the resin material by applying a predetermined energy to the resin material to adhere the net-like sheet 24 to the front member 21.

When the net-like sheet 24 is made of an olefin-based resin material such as PP or PE, the resin material of the irradiated portion is cured by irradiating the whole or a part of the net-like sheet 24 with an electron beam. , The adhesive portion 31 can be formed. Further, by causing the resin material of the irradiated portion to be crosslinked, the strength and heat resistance of the mesh sheet 24 can be improved, and the strength of the front member 21 can be improved. Further, when the entire mesh sheet 24 is irradiated with the electron beam, the back surface of the front member 21 is also irradiated with the electron beam. At this time, the back surface of the front member 21 is sterilized by electron beam irradiation, and the fluidity of the heat insulating material 40 can be improved.

When the net-like sheet 24 is made of an ultraviolet curable resin, the resin material of the irradiated portion is cured by irradiating the whole or a part of the net-like sheet 24 with ultraviolet rays, and the adhesive portion 31 is formed. Can be formed.

When irradiating radiation such as an electron beam or ultraviolet rays, first, the net-like sheet 24 is placed at an appropriate position on the back surface of the front member 21, and for example, the adhesive portion 31 as shown in FIGS. 7 and 8 is provided. Radiation may be locally applied to only the formation position as a target.

Alternatively, the entire area where the reticulated sheet 24 is arranged may be irradiated with radiation. As a result, a curing reaction can be generated in the entire region of the resin material forming the net-like sheet 24, and the rigidity of the net-like sheet 24 can be improved. In this way, by irradiating the mesh sheet 24 with radiation to cure the resin material forming the network sheet 24, the strength of the front member 21 to which the network sheet 24 is adhered can be improved. ..

As described above, the net-like sheet 24 has irregularities on its surface. Therefore, even if the entire mesh sheet 24 is irradiated with radiation, the portion where the recess 24b is formed is separated from the back surface of the front member 21, so that the adhesive portion 31 is not formed. Therefore, even if the entire network sheet 24 is irradiated with radiation, the entire network sheet 24 does not adhere to the back surface of the front member 21, and a gap is partially formed. Therefore, the heat insulating material can be filled in the gap between the mesh sheet 24 and the back surface of the front member 21.

(Summary)
As described above, in the refrigerator 1 according to the present embodiment, the mesh sheet 24 is arranged on the back surface of the front member 21 constituting the refrigerator compartment door 11. Thereby, the fluidity of the heat insulating material 40 when the heat insulating material 40 is dropped on the back surface of the front member 21 can be improved. Therefore, the heat insulating material 40 is filled more uniformly, and the heat insulating layer 23 having few voids can be formed. By having such a heat insulating layer 23, the formation of irregularities on the surface of the refrigerator compartment door 11 is suppressed, so that the quality of the appearance of the refrigerator 1 can be improved.

Further, even when the front member 21 is made of a thinner steel plate, the formation of irregularities on the front surface of the refrigerator compartment door 11 is suppressed, so that the appearance of the refrigerator 1 when viewed from the front is improved. Can be made to.

Further, on the surface of the net-like sheet 24, unevenness (convex portion 24a and concave portion 24b) is formed at least on the side facing the front member. As a result, the surface of the net-like sheet 24 has a portion that contacts the back surface of the front member 21 and a portion that does not contact the back surface of the front member 21. Therefore, the heat insulating material can be distributed even in the gap formed between the mesh sheet 24 and the front member 21.

Further, some of the convex portions 24a of the mesh sheet 24 formed on the side facing the front member 21 are adhered to the back surface of the front member 21. Thereby, in the step of injecting the heat insulating material at the time of manufacturing the refrigerating chamber door 11, it is possible to avoid the misalignment and floating of the net-like sheet 24 placed on the front member 21.

Further, the net-like sheet 24 may be made of a resin material having a property of being cured by applying a predetermined energy (for example, radiation, heat, etc.). As a result, the mesh sheet 24 can be adhesively fixed on the back surface of the front member 21 by applying a predetermined energy while the mesh sheet 24 is placed on the front member 21. Since the reticulated sheet 24 cured in this way has increased rigidity, as a result, the strength of the front member 21 to which the reticulated sheet 24 is attached can be improved.

In the above-described embodiment, the refrigerator compartment door 11 having a long rectangular shape in the vertical direction has been described as an example, but the above-mentioned manufacturing method is also applied to a heat insulating door having a long rectangular shape in the left-right direction. can do. In this case, it is preferable to move the injection head 51 of the injection device 50 along the left-right direction (longitudinal direction of the front member) of the heat insulating door. Then, in the rectangular opening of the mesh sheet 24, the mesh sheet 24 is placed on the front member so that the length L1 in the moving direction of the injection head 51 is smaller than the length L2 in the direction orthogonal to the moving direction. It is preferable to arrange it in.

Further, the above-mentioned manufacturing method of the refrigerator compartment door 11 can also be used when manufacturing a heat insulating door other than the refrigerator compartment door 11 (for example, a door of a heat insulating storage such as a freezer or a warmer).

[Second Embodiment]
Subsequently, a second embodiment of the present invention will be described. In the second embodiment, the structure of the net-like sheet arranged on the back surface of the front member is different from that of the first embodiment. For other configurations, the same configurations as in the first embodiment can be applied. Therefore, in the following, the points different from the first embodiment will be mainly described.

FIG. 9 shows the configuration of the net-like sheet 124 arranged on the front member 21 constituting the refrigerating room door 11 according to the second embodiment. In FIG. 9, the moving direction of the injection head 51 in the dropping step is indicated by an arrow. Further, in FIG. 9, the mesh shape of the mesh sheet 124 is enlarged and shown.

As shown in FIG. 9, the net-like sheet 124 is formed of a plurality of fibers extending in a direction inclined with respect to the vertical direction of the front member 21. The mesh sheet 124 has a grid-like mesh shape with rhombic openings. Here, the mesh shape of the mesh sheet 124 is a diamond shape in which the moving direction of the injection head 51 is shorter than the direction orthogonal to the moving direction. That is, in the diamond-shaped opening of the mesh sheet 124, the length L1 in the moving direction of the injection head 51 is smaller than the length L2 in the direction orthogonal to the moving direction.

Since the mesh shape of the mesh sheet 124 has the above-mentioned structure, the dropped heat insulating material 40 is promoted to flow in the longitudinal direction (direction of length L2) of the mesh (opening). .. As a result, the heat insulating material 40 can be further expanded in a direction orthogonal to the moving direction of the injection head 51 (that is, in the left-right direction of the refrigerating chamber door 11).

As for the material forming the net-like sheet 124 and the uneven shape of the surface of the net-like sheet 124, the same material as the net-like sheet 24 described in the first embodiment can be applied. Further, similarly to the net-like sheet 24, the net-like sheet 124 is formed by interweaving a plurality of fibers extending in the first direction and a plurality of fibers extending in the second direction intersecting the first direction. May be good. As a method of adhering the net-like sheet 124 to the back surface of the front member 21, the method described in the first embodiment can be applied.

[Third Embodiment]
Subsequently, a third embodiment of the present invention will be described. In the third embodiment, the structure of the net-like sheet arranged on the back surface of the front member is different from that of the first embodiment. For other configurations, the same configurations as in the first embodiment can be applied. Therefore, in the following, the points different from the first embodiment will be mainly described.

In the third embodiment, an example in which the net-like sheet is divided into a plurality of parts will be described. FIG. 10 shows the configuration of the net-like sheets 224a to 224d arranged on the front member 21 constituting the refrigerating room door 11 according to the third embodiment. In FIG. 10, the moving direction of the injection head 51 in the dropping step is indicated by an arrow.

In the refrigerator compartment door 11 according to the present embodiment, four mesh sheets 224a, 224b, 224c, and 224d are arranged on the back surface of the front member 21. Each of the reticulated sheets 224a, 224b, 224c, and 224d has the same configuration as the reticulated sheet 24 described in the first embodiment.

Specifically, the net-like sheet 224a is arranged so as to cover the area from the central portion to the upper right of the front member 21. The net-like sheet 224b is arranged so as to cover the upper left region from the central portion of the front member 21. The net-like sheet 224c is arranged so as to cover the lower right region from the central portion of the front member 21. The net-like sheet 224d is arranged so as to cover the lower left region from the central portion of the front member 21.

Further, the surfaces of the net-like sheets 224a to 224d are formed with irregularities as in the case of the net-like sheet 24 described in the first embodiment. Further, similarly to the mesh sheet 24, the mesh sheets 224a to 224d are formed by interweaving a plurality of fibers extending in the first direction and a plurality of fibers extending in the second direction intersecting the first direction. You may be.

As a method of adhering the mesh sheets 224a to 224d to the back surface of the front member 21, the method described in the first embodiment can be applied. Specifically, the adhesive portions 31 may be formed at intervals as shown in FIG. 7 or 8. At this time, it is preferable to provide a plurality of adhesive portions 31 for one net-like sheet.

[Fourth Embodiment]
Subsequently, a fourth embodiment of the present invention will be described. In the fourth embodiment, the structure of the net-like sheet arranged on the back surface of the front member is different from that of the first embodiment. For other configurations, the same configurations as in the first embodiment can be applied. Therefore, in the following, the points different from the first embodiment will be mainly described.

In the fourth embodiment, the net-like sheet is arranged at the drop start position and the region including the outside of the dropping of the heat insulating material 40 dropped from the injection head 51, and the drop end position and the region including the outside thereof, respectively. An example of this will be described. FIG. 11 shows the configurations of the mesh sheets 324a and 324b arranged on the front member 21 constituting the refrigerator compartment door 11 according to the fourth embodiment.

In FIG. 11, the moving direction of the injection head 51 in the dropping step is indicated by an arrow. Further, in FIG. 11, the dropping start position of the heat insulating material 40 dropped from the injection head 51 is shown as A, and the dropping end position is shown as B.

As shown in FIG. 11, in the refrigerator compartment door 11 according to the present embodiment, two net-like sheets 324a and 324b are arranged on the back surface of the front member 21. The net-like sheet 324a is arranged above the front member 21. The mesh sheet 324b is arranged below the front member 21.

Specifically, the net-like sheet 324a is arranged in a region including the drop start position A of the heat insulating material 40 dropped from the injection head 51 and the upper side thereof. Further, the net-like sheet 324b is arranged in a region including the end position B of dropping the heat insulating material 40 dropped from the injection head 51 and the lower side thereof.

By arranging the mesh sheet 324a in the above-mentioned region on the front member 21, the heat insulating material 40 dropped on the front member 21 starts dropping from the dropping start position A along the arrangement position of the mesh sheet 324a. It is guided in the direction of expanding upward. Further, since the mesh sheet 324b is arranged in the above-mentioned region on the front member 21, the heat insulating material 40 dropped on the front member 21 is placed at the end position of dropping along the arrangement position of the mesh sheet 324a. It is guided in the direction of expanding downward from B. As a result, the heat insulating material 40 can be more reliably guided to the upper end side and the lower end side of the front member 21 where the heat insulating material 40 after dropping is difficult to spread.

As for the configurations of the reticulated sheets 324a and 324b, the configurations described in the first embodiment or the second embodiment can be applied. Further, as a method of adhering the net-like sheets 324a and 324b to the back surface of the front member 21, the method described in the first embodiment can be applied.

In each of the above-described embodiments, as an example of the present invention, a heat insulating door of a refrigerator has been described as an example. However, the present invention is not limited to this. The heat-insulating door according to the present invention can be applied to, for example, the door of a heat-insulating storage such as a heat-retaining refrigerator or a freezer.

It should be considered that the embodiments disclosed this time are exemplary in all respects and not restrictive. The scope of the present invention is shown by the scope of claims rather than the above description, and it is intended to include all modifications within the meaning and scope equivalent to the scope of claims. In addition, a configuration obtained by combining the configurations of different embodiments described in the present specification with each other is also included in the scope of the present invention.

1: Refrigerator 11: Refrigerator door (insulation door)
12: Freezing room door (insulation door)
21: Front member (front member)
22: Door back (back side member)
23: Insulation layer (foam insulation)
24: Reticulated sheet (reticulated sheet member)
24a: Convex part 24b: Concave part 25: Fiber (linear body) extending in the first direction
26: Fiber (linear body) extending in the second direction
31: Adhesive part 50: Injection device (of heat insulating material) 51: Injection head 124: Reticulated sheet (reticulated sheet member)
224a: Reticulated sheet (reticulated sheet member)
224b: Reticulated sheet (reticulated sheet member)
224c: Reticulated sheet (reticulated sheet member)
224d: Reticulated sheet (reticulated sheet member)
324a: Reticulated sheet (reticulated sheet member)
324b: Reticulated sheet (reticulated sheet member)

Claims (8)

Front side member and
The back side member arranged to face the front side member,
A heat insulating layer located between the front side member and the back side member and having a foamed heat insulating material,
A heat insulating door that is arranged on the back surface of the front surface side member and includes a mesh-like sheet member that has irregularities on the back surface. At least a part of the mesh sheet member is adhered to the back surface of the front surface side member.
The heat insulating door according to claim 1. The heat-insulating door according to claim 2, wherein the adhesive portion of the mesh-like sheet member with the back surface of the front surface member is obtained by curing a resin material. The heat insulating door according to any one of claims 1 to 3, wherein the mesh-like sheet member is formed by weaving a plurality of linear bodies. The heat insulating door according to any one of claims 1 to 4, wherein the mesh-like sheet member is obtained by at least partially curing a resin material. The heat insulating door according to any one of claims 1 to 5, wherein the mesh-like sheet member is adhered to the back surface of the front surface side member by irradiating with an electron beam. The heat insulating layer is formed by dropping a foamed heat insulating material from an injection head that moves along the longitudinal direction of the front surface member.
The heat insulating property according to any one of claims 1 to 6, wherein the mesh-like sheet member has a mesh shape in which the longitudinal direction of the front surface member is shorter than the direction orthogonal to the longitudinal direction. door. A refrigerator provided with the heat insulating door according to any one of claims 1 to 7.

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