JP7261758B2 - Door, manufacturing method thereof, and refrigerator provided with door - Google Patents

Description

The present invention relates to a door, its manufacturing method, and a refrigerator provided with a door.

2. Description of the Related Art As a door of a refrigerator, a door having an outer plate and a frame plate positioned on the side of the outer plate is known. Since the outer plate and the frame plate are fixed with an adhesive or the like, if the adhesive flows out to the front surface of the outer plate, the aesthetic appearance is spoiled, and it is likely to be treated as a poor appearance.

Patent Document 1 describes a structure in which a transparent member 40 as an outer plate is adhered to a main surface 50. A plurality of projecting portions 56 that are discretely arranged and are in contact with the rear main surface of the transparent member 40, and a projecting portion Disclosed are grooves 52 located at a more outer periphery to store the adhesive (0050-0054, FIG. 3).

In Patent Document 1, a thermoplastic hot-melt adhesive is applied to the main surface 50 by a coating device along a door frame 42A as a frame plate having a substantially frame shape on a belt conveyor 60 so as to draw a rectangular shape. , the transparent member 40 is placed on the door frame 42A (S13). Later, a pressing force is evenly applied from above (S14) (0064-0075, FIG. 5-8). Excess adhesive is stored in the groove 52 to prevent it from flowing out (0078).

JP 2016-161219 A

In Patent Document 1, it is necessary to form an unnecessary groove portion 52 in the door frame 42A itself. It is desirable to suppress the leakage of the adhesive when the transparent member 40 is placed on the door frame 42A without the groove portion 52 being presupposed. In considering the means, the inventors of the present invention, for example, set the transparent member 40 at an angle to block the leakage path, more specifically, cover substantially the entire side of the door frame 42A. The inventors have found that it is effective to place the transparent member so that substantially the entire side thereof is in contact with the transparent member.

By the way, it is conceivable to form the door frame 42A by assembling a plurality of members. For example, in the case of a rectangular door frame, four members corresponding to each side may be assembled. In this case, when assembling the four members, there is a concern that the members forming each side are originally warped, or that the members are warped due to residual stress or the like during assembly. If it is warped, it is difficult to contact substantially the entire substantially linear side of the transparent member 40, so that the leakage path cannot be completely blocked. For this reason, when using an assembly type door frame, by using a device that applies a correcting force to correct the warpage, it becomes easier to place the door frame so as to block the leakage path as described above.

The present invention, which has been made in view of the above circumstances,
A door manufacturing method including a step of adhering an outer panel to a door frame using a holding device having a holding portion,
a holding step of holding a first frame as a part of the door frame with the holding portion;
a first application step of applying an adhesive to the outer plate or the first frame;
a first placing step of placing the outer plate on the first frame,
The first frame is
a first flange portion including at least a portion of a first adhesion region that is adhered to the skin by the adhesive;
a first opposing portion extending from the root side of the first flange portion toward the outer plate side of the first flange portion;
In the holding step, a pressing force is applied in the lateral direction of the first frame ,
The door frame is
a second flange portion including at least a portion of a second adhesion region that adheres to the skin with an adhesive;
a second frame including a second facing portion extending from the base of the second flange portion toward the outer plate than the second flange portion;
The second frame has an adhesive release portion capable of storing adhesive outside the second adhesive region,
The manufacturing method of displacing the second frame in a direction away from the outer panel when the outer panel is substantially in contact with the adhesive applied to the second adhesive region.

Front view of the refrigerator of the embodiment Exploded perspective view of right pivoting heat insulating door FIG. 3 is a cross-sectional view schematically showing the main part of FIG. 2 Enlarged cross-sectional view showing the flange portion and its surroundings in FIG. Top view of the holding device for the frame of the heat insulating door Top view of the holding device and the transfer robot that transfers the outer plate Side cross-sectional view of a state in which the transport robot is in the middle of placing the outer panel on the door frame of the holding device. Side cross-sectional view of a state in which the transport robot has finished placing the outer panel on the door frame of the holding device.

In the following description, the “front” side means the outer plate 10 side of the refrigerator 1 , and the “back” side means the inner plate 60 side of the refrigerator 1 .

Drawing 1 is a front view of refrigerator 1 of an embodiment. A refrigerator 1 includes a refrigerator compartment 2 , an ice making compartment 3 , an upper switching compartment 4 , a lower freezing compartment 5 and a vegetable compartment 6 . The dashed lines in the drawing indicate the flange portions (right flange portion 21a, left flange portion 22a, upper flange portion 23a, lower flange portion 24a) to which the reactive hot-melt adhesives 70 and 70A are applied.

Refrigerator 1 includes rotary heat insulation doors 2a and 2b that open and close refrigerator chamber 2 around hinges 7a and 7b, a drawer heat insulation door 3a that opens and closes ice making chamber 3, and a drawer that opens and closes switching chamber 4. A drawer-type heat insulation door 4a for opening and closing the lower freezer compartment 5, and a drawer-type heat insulation door 6a for opening and closing the vegetable compartment 6 are provided.

FIG. 2 is an exploded perspective view of the pivotable right heat insulating door 2a. FIG. 3 is a cross-sectional view taken along line III-III of FIG. FIG. 4 is an enlarged sectional view showing left and right flange portions 21a, 22a and their surroundings in FIG.

The heat insulating door 2a includes an outer plate 10 provided on the surface of the heat insulating door 2a, an inner plate 60 provided on the back surface, a door frame 20 provided on four sides of the outer plate 10 and the inner plate 60, and an outer and a vacuum insulation material 30 disposed on the back surface of the plate 10 . A space 40 formed by the outer plate 10, the door frame 20, and the inner plate 60 is provided with, or preferably filled with, a vacuum heat insulating material 30 and a foam heat insulating material 50. As shown in FIG. The structure of the door 2b can be reversed to the left and right of the door 2a.

The outer plate 10 is a substantially rectangular flat plate member forming a design surface, which is the surface of the heat insulating door 2a, and can be made of, for example, glass, resin, or steel plate. It is preferable to use a material having a coefficient of linear expansion smaller than that of the material of the door frame 20 .

The door frame 20 is made of ABS (acrylonitrile-butadiene-styrene copolymer) resin, for example. The door frame 20 is formed by assembling two or more members, and is formed of four members of a right frame portion 21, a left frame portion 22, an upper frame portion 23, and a lower frame portion 24 in this embodiment. Adhesive 70 is applied to each frame portion 21-24, and flat plate-shaped flange portions 21a-24a including regions to which the back surface of the outer plate 10 is adhered contact or face the side end surfaces of the outer plate 10. Opposing portions 21e-24e, flange portions, and side peripheral portions 21b-24b that are integrally formed with or mechanically connected to the opposing portions and extend in the front-rear direction are formed. The outer plate 10 and the door frame 20 are bonded to each other by contacting the outer surface of the outer plate 10 with the front sides of the flange portions 21a to 24a to which the adhesive 70 is applied. Each of the frames 21-24 has an engaging structure (not shown) that engages with the adjacent frame.

The outer plate 10 and the door frame 20 will be described as a representative of the left and right structures. The upper and lower structures can also be made in the same way. Chamfered portions 10a1 and 10a2 are formed at the left ends of the front and back surfaces of the outer plate 10, respectively, and chamfered portions 10b1 and 10b2 are formed at the right ends thereof. The left flange portion 22a has an opposing portion 22e having a linear cross-section that protrudes forward from the root and abuts the left end surface of the outer plate 10. As shown in FIG. The right flange portion 21a is formed with a facing portion 21e having a substantially L-shaped cross-section that protrudes from the root and then extends leftward to contact the right end face of the outer plate 10. As shown in FIG. A gap S1 exists between the facing portion 21e and the right end surface of the outer plate 10, and an adhesive release portion 21z exists between the root side of the flange portion 21a and the facing portion 21e. The gap S1 is positioned outside the refrigerator 1 in the left-right direction. That is, the door 2a is located on the right side, and the door 2b is located on the left side.

The outer plate 10 and the flanges 21a-24a are bonded with an adhesive 70, which is, for example, a reactive hot-melt adhesive. In this embodiment, all four sides of the outer panel 10 are adhered with the adhesive 70, but the adhesive 70 may be applied only on two or three sides, for example. The adhesive 70 may be applied to the base of the flange portion (that is, the side near the side circumference portion 21) exactly, but it is preferably applied only inside the area where the outer panel 10 is initially placed. . For this reason, in this embodiment, the adhesive 70 is applied to a position slightly spaced from the root and to a region farther from the root.

As the vacuum heat insulating material 30, a known heat insulating material can be used, for example, a core material such as glass wool having a porous structure is vacuum-packed with a laminate film, and the inside is depressurized and sealed. The vacuum heat insulating material 30 is formed in a flat plate shape and adhered to the back side of the outer plate 10 . The vacuum heat insulating material 30 is smaller in front view size than the outer plate 10 , and a part of the space 40 exists between the vacuum heat insulating material 30 side and the door frame 20 . This portion can also be filled with foam insulation 50 .

The foamed heat insulating material 50 as a hard urethane foam is formed by curing after foaming a urethane foam undiluted solution (raw heat insulating material liquid) injected into the space 40 inside the heat insulating door 2a. As the urethane foam stock solution, for example, a solution obtained by premixing a polyether polyol with a foaming agent such as cyclopentane and water, as well as an auxiliary agent such as a catalyst and a foam stabilizer, and an isocyanate solution can be used. .

The inner plate 60 is a plate member made of resin (such as ABS) provided on the storage room side of the heat insulating door 2a, and is fixed to the rear peripheral portion of the door frame 20. As shown in FIG.

Reactive hot melt, for example, can be used as the adhesive 70 . This is not a general thermoplastic hot melt (which melts when heat is applied), but has the property of not melting when heat is applied. In addition, the reactive hot-melt has good initial strength, little dimensional change after curing, excellent moisture resistance and weather resistance, and does not melt again. Such a reactive hot-melt is, for example, an adhesive obtained by mixing a prepolymer and an isocyanate, and the reaction progresses using moisture (in the air) after being heated and melted. Specifically, PUR (poly urethane reactive), POR (poly olefin reactive), and the like can be applied. Of course, it is not meant to intentionally exclude thermoplastic adhesives.

For the adhesive 70, when an inexpensive material such as PE (polyethylene) or difficult-to-adhere PP (polypropylene) is used for the door frame 20, POR, which is the same olefin-based hot melt, may be used. is desirable. Even if the door frame 20 is made of an inexpensive material instead of ABS, good adhesion can be obtained by applying POR. In addition, stable bonding strength can be obtained by bonding after the surface temperature of the outer plate 10 and the door frame 20 is set to 20° C. or higher under the ambient temperature conditions during assembly.

FIG. 5 is a top view of the holding device 100 for the frame body (frame members 21 to 24) of the heat insulating door. FIG. 6 is a top view of the holding device 100 and the transfer robot 120 that transfers the outer plate.

The holding device 100 includes a fixed surface 102 and a fixed surface facing movable portion 103 facing each other, a fixed surface side inner movable portion 104 and a fixed surface side outer movable portion 105, a far fixed surface side inner movable portion 106 and a far fixed surface side outer movable portion. It has a portion 107 , a near fixed surface side inner movable portion 108 and a near fixed surface side outer movable portion 109 . The movable parts 103 to 109 are movable in the lateral direction of the placed frame members 21 to 24, respectively, and thereby press the frame members 21 to 24 from both sides in the lateral direction, thereby moving the frame members 21 to 24 respectively. It can be deformed in a direction to eliminate the warp.

The fixed surface 102 is a fixed member that contacts and positions at least two adjacent sides of the frame body.

The fixed-surface facing movable portion 103 is a member that faces one side of the fixed surface 102, preferably the longer side, and is movable in the opposite direction.

The fixed-surface-side inner movable portion 104 and the fixed-surface-side outer movable portion 105 are members that are provided substantially on extension lines of other sides of the fixed surface 102, preferably shorter sides, and face each other. At least one of these is movable in opposite directions. Both are movable in this embodiment.

The far fixed surface side inner movable part 106 and the far fixed surface side outer movable part 107, the near fixed surface side inner movable part 108 and the near fixed surface side outer movable part 109 are opposed to each other, and at least one of them moves in the opposite direction. It is a flexible member.

The number of pairs of fixed surfaces or outer movable portions and inner movable portions facing each other (hereinafter referred to as opposing pairs) is the same as the number of members constituting the frame. For this reason, four sets are prepared in this embodiment, and the left frame portion 22 is placed between the fixed surface 102 and the fixed surface opposing holding portion 103, and the fixed surface side inner movable portion 104 and the fixed surface side outer movable portion are mounted. 105, the right frame portion 21 is placed between the far fixed surface side inner movable portion 106 and the far fixed surface side outer movable portion 107, and the near fixed surface side inner movable portion 108 , and the near fixed surface side outer movable portion 109, the lower frame portion 24 is placed.

When assembling the frame, first, the frames 21 to 24 are placed as described above. The fixing surface 102 is used to position and engage the left frame portion 22 and the upper frame portion 23 as two adjacent sides. The warp is corrected by applying a pressing force to each of the frame portions 21 to 24 by shortening the facing distance of each facing set. Since the left and right frame portions 21 and 22, which are long sides, are particularly susceptible to warping, it is preferable to apply a pressing force to at least these two sets. A movable portion is provided on at least one side of the frame portion to press the frame portion, and a movable portion or a fixed portion is provided on the other side to restrict movement of the frame portion receiving a pressing force from one side. . This makes it possible to reduce or eliminate warping of the frame. Application of the pressing force to a certain frame is preferably continued until the outer plate 10 finishes contacting or being placed on this frame.

For example, the lower frame portion 24 adjacent to the left frame portion 22 of the outer plate 10 is held so as to be sandwiched between the fourth outer holding portion 109 and the fourth inner holding portion 108 in the operating directions 116 and 115 .

The transfer robot 120 includes a seat 123 that is freely rotatable in top view, an arm 121 that is connected to the seat 123 at one end and is rotatable around an axis, and a suction surface 122 that is connected to the other end of the arm 121 and is capable of sucking the outer plate 10 . have. The suction surface 122 can move in and out of the region directly above the holding device 100 by rotating the seat 123, and can adjust the angle θ in the side view direction of the attracted outer plate 10 by rotating the arm 121. FIG. Preferably, there are no or no moving parts that change the top view orientation of the skin 10 being transported by the transport robot 120 .

The transport robot 120 places the outer panel 10 on the flanges 21 a to 24 a of the frame attached to the transport device 100 and coated with the adhesive 70 . Although the adhesive 70 is applied to the door frame 20 in this embodiment, it may be applied to the outer plate 10 . For this reason, the area where the outer plate 10 and the door frame 20 are adhered, that is, the area where the adhesive 70 is applied is called the adhesion area.

7 is a cross-sectional side view of a state in which the transport robot 120 is in the process of placing the outer panel 10 on the door frame 20 of the holding device 100 as viewed from arrow AA in FIG. FIG. 8 is a cross-sectional side view of a state in which the transfer robot 120 has finished placing the outer panel 10 on the door frame 20 of the holding device 100 as viewed from the arrow AA.
. The outer plate 10 sucked and conveyed by the suction surface 122 reaches just above the frame. The outer plate 10 is adjusted so that the inclination angle θ that can be seen in the AA arrow (side view) is, for example, 15 to 60° in this directly overhead region. θ is 90° when the outer plate 10 is placed on the door frame.

In the present embodiment, first, the outer plate 10 is placed so that the left end surface of the outer plate 10 is slanted downward so that the left end surface of the outer plate 10 abuts against the left facing portion 22e. An adhesive 70 is applied to a region of the flange portion 22a spaced apart from the facing portion 22e (root of the flange portion 22a). As a result, when the left end surface of the outer plate 10 abuts against the left frame portion 22, the adhesive 70 is left and right inside the abutting area. As a result, the contact area between the left end surface of the outer plate 10 and the left frame portion 22 blocks the leakage path of the adhesive 70 . Since substantially the entire long side of the left frame portion 22 is compressed in the lateral direction by the holding device 100, the warping is eliminated, so that the leak path can be effectively blocked.

Next, the right side of the outer plate 10 is placed on the right frame portion 21 by increasing θ. Since the adhesive release portion 21z is present on the right side, the adhesive 70 is prevented from leaking out to the front of the outer plate 10 through the space between the right end surface of the outer plate 10 and the facing portion 21e during mounting. Further, in this embodiment, when the right side of the outer plate 10 is placed on the right frame portion 21, the holding device 100 is driven at the timing when the outer plate 10 contacts the adhesive 70 of the right flange portion 21a, and the right frame portion 21 is displaced to the right 113 and immediately thereafter to the left 114 . As a result, the gap S1 can be enlarged when the adhesive 70 is crushed and expanded, so that the leakage of the adhesive 70 to the front of the outer plate 10 is further suppressed. This timing can be determined by monitoring the value of θ, for example.

In this embodiment, the right frame portion 21 and other frame portions are also compressed in the lateral direction. As a result, warping of the right frame portion 21 and other frame portions can be reduced, so that the appearance of the finished product can be improved.

1 refrigerator 2a heat insulating door 10 outer plate 20 door frame 21 right frame portion 22 left frame portion 23 upper frame portion 24 lower frame portions 21a, 22a, 23a, 24a flange portions 70, 70a reactive hot melt adhesive 100 holding device 120 transport Device S1, S2 Gap

Claims (6)

A door manufacturing method including a step of adhering an outer panel to a door frame using a holding device having a holding portion,
a holding step of holding a first frame as a part of the door frame with the holding portion;
a first application step of applying an adhesive to the outer plate or the first frame;
a first placing step of placing the outer plate on the first frame,
The first frame is
a first flange portion including at least a portion of a first adhesion region that is adhered to the skin by the adhesive;
a first opposing portion extending from the root side of the first flange portion toward the outer plate side of the first flange portion;
In the holding step, a pressing force is applied in the lateral direction of the first frame ,
The door frame is
a second flange portion including at least a portion of a second adhesion region that adheres to the skin with an adhesive;
a second frame including a second facing portion extending from the base of the second flange portion toward the outer plate than the second flange portion;
The second frame has an adhesive release portion capable of storing adhesive outside the second adhesive region,
The manufacturing method of displacing the second frame in a direction away from the outer panel when the outer panel is substantially in contact with the adhesive applied to the second adhesive region. 2. The manufacturing method according to claim 1, wherein the first adhesive region is a region spaced apart from the base of the first flange portion. The outer plate has a first side end face on the first frame side and a second side end face facing the first side end face,
3 . The manufacturing method according to claim 1 , wherein in the first placing step, the outer plate is placed obliquely such that the first side end surface is located below the second side end surface. 4. The manufacturing method according to any one of claims 1 to 3 , wherein the door in a state in which bonding is completed has a gap between the outer panel and the second frame. A door manufactured by the manufacturing method according to any one of claims 1 to 4 . A refrigerator having a door manufactured by the manufacturing method according to any one of claims 1 to 4.

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