JP5689387B2 - Refrigerator and manufacturing method thereof - Google Patents

Description

The present invention relates to a refrigerator and a manufacturing how using the vacuum heat insulating material.

  Recently, from the viewpoint of protecting the global environment such as prevention of global warming, attention has been focused on reducing carbon dioxide emissions worldwide. Refrigerators have been focused on reducing power consumption as a measure to save energy, and it is thought that they contributed to the reduction of carbon dioxide emissions. However, refrigerators with low power consumption will continue to be demanded in order to meet the power-saving needs that are spreading globally like now.

On the other hand, as a recent social background, due to the trend of couples working together and becoming a nuclear family, the number of households buying foods on weekend holidays is increasing, and the need for a large capacity refrigerator is increasing.
Conventionally, in order to save energy in refrigerators, investigations have been made to improve the heat insulation performance of refrigerator boxes, and products that have significantly improved heat insulation performance by combining vacuum insulation with rigid urethane foam have been released (market) Distributed). Here, the vacuum heat insulating material generally has a heat insulating performance 10 times or more that of rigid urethane foam. In order to improve the heat insulation performance of the refrigerator, it is one of the options to use more vacuum heat insulating materials with good heat insulation performance.

There exists the following patent document 1 as a prior art example of the refrigerator using a vacuum heat insulating material.
FIG. 9 is a perspective view showing a state in the middle of manufacturing the heat insulating box body of Patent Document 1. FIG.
In Patent Document 1, three vacuum fillers 201a are connected to each other at predetermined intervals on a flat iron plate 207 constituting the left and right side wall surfaces and the ceiling surface of a heat insulating box outer box forming a box of a refrigerator. An example is shown in which the iron plate 207 is bent together with the vacuum heat insulation panel 201 after the vacuum heat insulation panel 201 having the seal portion is arranged in the connection portion 202a having the predetermined interval and arranged with the 202a present. In addition, the broken line of the connection part 202a in FIG. 9 has shown the bending location.

  Thereby, since the ratio of the length of the end surface of the joint part (connection part 202a) to the internal volume of the exterior body (vacuum heat insulation panel 201) is reduced, it is possible to suppress the heat insulation performance deterioration of the vacuum heat insulation panel 201 during long-term use. In addition, an example is shown in which a beneficial effect that the manufacturing workability can be greatly improved is shown.

FIG. 10 is a cross-sectional view in an exploded state when the vacuum heat insulating material of Patent Document 2 is attached to the outer box of the refrigerator.
Further, in Patent Document 2, a plurality of vacuum heat insulating materials 311A, 311B, 311C, and 311D are covered with each other in a heat insulating box 320 and 321 provided with a plurality of independent vacuum heat insulating materials 311A, 311B, 311C, and 311D. An example is shown in which the vacuum heat insulating material 301 is attached to adjacent wall surfaces such as the left and right side surfaces 320A and 320C, the ceiling surface 320B, and the back surface 320D of the heat insulating box 320 at a time by heat welding and connecting.

FIG. 11 is an exploded rear perspective view of the refrigerator before filling with the foam heat insulating material of Patent Document 3.
Patent Document 3 shows an example of the refrigerator 401 in which a vacuum heat insulating material 470 is disposed across the left and right side plates 402A and the back plate 402C of the outer box 402 of the refrigerator 401.

Japanese Patent Laid-Open No. 7-98090 Japanese Patent Laid-Open No. 7-9656 Japanese Patent Laid-Open No. 10-205992

  In recent years, various industries have promoted energy saving of various so-called electric appliances including home appliances such as household refrigerators as part of global environmental protection. Among them, in order to improve the heat insulation performance of the box in the refrigerator for home use, a vacuum heat insulating material with high heat insulation is being adopted more and more than ever.

Specifically, there are cases where vacuum heat insulating materials are arranged on all or part of the left and right side surfaces, ceiling surface, back surface, bottom surface and door surfaces of the refrigerator, and the use area of the vacuum heat insulating materials tends to increase. It has become.
However, in order to further promote energy saving that will continue in the future, it is necessary to increase the size (heat insulation area) per vacuum insulation material or increase the thickness (reduction of heat transfer). However, in the space between the outer box and the inner box of the refrigerator, in addition to the vacuum heat insulating material, various parts (heat radiating pipes, control parts, etc.) are arranged, which is quite difficult.

  Here, the reason why the size per vacuum heat insulating material is enlarged will be described. The vacuum heat insulating material is a material in which a material having a high porosity is covered with an outer packaging material having a very low gas and moisture permeability, and the inside thereof is decompressed.

  On the other hand, so-called foamed heat insulating materials such as rigid urethane foam and styrofoam, and so-called fiber heat insulating materials such as glass wool and rock wool are used as independent heat insulating materials. The heat insulation performance of these heat insulation materials, including vacuum heat insulation materials, is determined mainly by three heat transfer performances: solid heat transfer, gas heat transfer, and radiation heat transfer. Since the vacuum heat insulating material which makes the inside a pressure-reduced state has small gas heat transfer, favorable heat insulation performance is obtained.

  However, as described above, the vacuum heat insulating material is provided with the outer packaging material, and in order to maintain the internal reduced pressure state for a long period of time, it is necessary to suppress the permeation of gas and moisture. Therefore, many of the outer packaging materials employ a laminated film including a metal foil or a metal vapor deposition layer. In the case of vacuum insulation, the actual insulation performance is worse than the apparent insulation performance (thermal conductivity) due to the influence of heat bridge (heat wraparound) that heat is transmitted through the outer packaging material containing this metal layer. Is the feature.

Foamed heat insulating materials, fiber heat insulating materials, and the like are hardly affected by the heat bridge.
The influence of the heat bridge of the vacuum heat insulating material depends on the size (area) of the core material of the vacuum heat insulating material, and the influence is relatively reduced as the core material is larger. Increasing the size as much as possible increases the heat insulation area and reduces the influence of the heat bridge, contributing to the improvement of the heat insulation performance of the refrigerator.

  About the vacuum heat insulation panel 201 (refer FIG. 9) shown by patent document 1, in the flat iron plate 207 which comprises the left-right side wall surface and ceiling surface of the heat insulation box outer box of a refrigerator so that the magnitude | size may be expanded. An example is shown in which the iron plate 207 is bent after the vacuum heat insulation panel 201 provided with three fillers 201a provided with a connection portion 202a having a predetermined interval and having a seal portion therebetween. However, since the filler 201a of the vacuum heat insulation panel 201 does not exist in the bent portion of the iron plate 207, that is, the corner portion of the heat insulation box, the heat insulation performance of the corner portion is insufficient. Therefore, the idea of suppressing the amount of heat leakage from the corner portion of the heat insulating box is insufficient.

About the vacuum heat insulating material 301 shown by patent document 2, the example which can be stuck on the several wall surface of the heat insulation box 320 by connecting several independent vacuum heat insulating material 311A, 311B, 311C, 311D at once is shown. Yes.
However, interference between the vacuum heat insulating materials 311A, 311B, 311C, and 311D when folded along the adjacent wall surfaces of the heat insulating box 320 (the back surface 320D and the left and right side surfaces 320A and 320C, the back surface 320D and the ceiling surface 320B, etc.). However, since there is no filler in the bent portion 311o, the heat insulating performance of the bent portion (the bent portion 311o) is insufficient, as in Patent Document 1, The idea of suppressing the amount of heat leakage from the corner portion (bent portion 311o) of the heat insulating box 320 is insufficient.

Moreover, when the filler of a vacuum heat insulating material is made to exist also in the corner part of a heat insulation box in order to solve the subject of patent documents 1, 2, the following two new problems will arise.
When the vacuum heat insulating panel 201 of the vacuum heat insulating material is attached to the iron plate 207 as in Patent Document 1 in FIG. 9, the filler in the corner portion becomes resistance, and bending is difficult, and Patent Document 2 in FIG. Assuming that the vacuum heat insulating material 301 is formed by bending the vacuum heat insulating material 301 in advance to attach the vacuum heat insulating material 301 to a plurality of wall surfaces (320A, 320B, 320C, 320D) at once, There is a new problem that it is difficult to apply a plurality of molded surfaces to a plurality of wall surfaces (320A, 320B, 320C, 320D) at the same time.

  In other words, in order to improve the heat insulation performance of the box, which is the basic performance of the refrigerator, there is a tendency to use a lot of vacuum heat insulating material, but in the case of vacuum heat insulating material consisting of a core material formed by a conventional binder or heating, the outer box is bent. It is difficult to place them in departments.

  Moreover, about the refrigerator 401 shown by patent document 3 of FIG. 11, in order to suppress the influence of a heat bridge, the left-right side board 402A and back board of the refrigerator 401 are enlarged so that the size per vacuum heat insulating material may become large. An example using a vacuum heat insulating material 470 straddling 402C is shown.

  However, while the iron plate constituting the outer box 402 of the refrigerator 401 is connected to the left and right side plates 402A and the top plate 402D, the shape of the vacuum heat insulating material 470 is the right and left side plates (side walls) 471 and the back plate (back wall) 473. Since the vacuum heat insulating material 470 is incorporated after the outer box 402 is assembled, the large size vacuum heat insulating material 470 as in Patent Document 3 is placed between the outer box 402 and the inner box 403. Adhering to the outer box 402 after being inserted into this space is a rather difficult operation.

  Since various parts such as a heat radiating pipe and a casing of the control unit are arranged between the outer box 402 and the inner box 403 of the refrigerator 401, the vacuum heat insulating material 470 hits these parts and rubs against them. There is a high risk of occurrence of perforations. In addition, an adhesive for fixing the vacuum heat insulating material 470 is applied to the left and right side plates 402A, the back plate 402C, and the top plate 402D that are the outer plates in advance, while being inserted between the outer box 402 and the inner box 403. Bonding is practically difficult.

In view of the above circumstances, also reduce heat leakage without degrading the heat insulating performance, workability and assembling efficiency is the sole purpose of providing good refrigerator and a manufacturing how the heat-insulating main body corners.

In order to achieve the above object, a refrigerator according to the first aspect of the present invention is a refrigerator including a heat insulating material and a vacuum heat insulating material between an outer box forming an outer shell and an inner box forming a storage chamber, The outer box is formed to include a plate material formed in a shape in which a plurality of flat plates are bent at a bending portion, and the vacuum heat insulation is performed on the inner box side surface of the plate material so as to straddle the plurality of flat plates. The vacuum heat insulating material is disposed on the plate of the outer box by bonding and a non-bonding portion is provided in the vicinity of the bent portion , and the vacuum heat insulating material is non-bonded. The portion is formed longer than the length of the non-bonded portion of the plate material facing the non-bonded portion .

According to a second aspect of the present invention, there is provided a refrigerator manufacturing method comprising: a vacuum heat insulating material disposed along the inner side surface of a plate member of an outer box forming a top plate and a side plate forming an outer shell of the refrigerator; In addition to being bonded, a portion facing the top plate is formed longer than the top plate so as not to be bonded to the top plate, and a clearance is formed between the vacuum heat insulating material and the top plate .

According to the present invention, also reduce heat leakage without degrading the heat insulating performance in the heat-insulating main body corners, processability and assembling property can be achieved a good refrigerator and a manufacturing how.

It is a front view of the refrigerator using the vacuum heat insulating material of embodiment concerning this invention. It is AA sectional view taken on the line of the refrigerator of FIG. It is XX sectional drawing of the refrigerator of FIG. It is a cross-sectional view which shows the vacuum heat insulating material used for the refrigerator of Embodiment 1. It is the figure which showed an example of the manufacturing process of the refrigerator of Embodiment 1. FIG. It is the figure which showed an example of the manufacturing process of the refrigerator of Embodiment 1. FIG. It is the figure which showed an example of the manufacturing process of the refrigerator of Embodiment 1. FIG. It is the figure which showed an example of the manufacturing process of the refrigerator of Embodiment 1. FIG. It is the figure which showed an example of the manufacturing process of the refrigerator of Embodiment 2. It is the figure which showed an example of the manufacturing process of the refrigerator of Embodiment 2. It is the figure which showed an example of the manufacturing process which adhere | attaches the vacuum heat insulating material of Embodiment 3 on an outer box steel plate, after bend | folding in U shape so that it may match the portal shape of an outer box steel plate. It is the figure which showed an example of the manufacturing process which adhere | attaches the vacuum heat insulating material of Embodiment 3 on an outer box steel plate, after bend | folding in U shape so that it may match the portal shape of an outer box steel plate. It is the figure which showed an example of the manufacturing process which adhere | attaches and arrange | positions the vacuum heat insulating material of Embodiment 3 in the flat state before bending an outer case steel plate. It is the figure which showed an example of the manufacturing process which adhere | attaches and arrange | positions the vacuum heat insulating material of Embodiment 3 in the flat state before bending an outer case steel plate. It is a perspective view which shows the state in the middle of manufacture of the heat insulation box of patent document 1. It is sectional drawing of the decomposition | disassembly state in the case of sticking the vacuum heat insulating material of patent document 2 on the outer box of a refrigerator. It is a decomposition | disassembly back perspective view of the refrigerator before being filled with the foam heat insulating material of patent document 3. FIG.

Embodiments of the present invention will be described below with reference to the accompanying drawings.
FIG. 1 is a front view of a refrigerator using a vacuum heat insulating material according to an embodiment of the present invention, and FIG. 2 is a cross-sectional view of the refrigerator of FIG.
The refrigerator 1 of the embodiment includes a refrigerator room 2, an ice making room 3a, a switching room (upper freezer room) 3b, a lower freezer room 4, and a vegetable room 5 from above.
The refrigerator compartment doors 6 a and 6 b of the refrigerator 1 are so-called double doors that rotate around hinges 10 a and 10 b, respectively, and are doors that open and close the front opening of the refrigerator compartment 2.

The ice storage room door 7a, the upper freezing room door 7b, the lower freezing room door 8, and the vegetable room door 9 open and close the front openings of the ice making room 3a, the upper freezing room 3b, the lower freezing room 4, and the vegetable room 5, respectively. It is a door, and all are drawer type doors.
When these drawer type doors (7a, 7b, 8, 9) are pulled out, the containers forming the ice making chamber 3a, the upper freezing chamber 3b, the lower freezing chamber 4, and the vegetable chamber 5 are pulled out together with the doors. Come.
In each door 6a-9, packing 11 (refer FIG. 2) for sealing the box 1H which comprises the main body of the refrigerator 1, and each door 6a-9 is the box 1H which defines each door 6-9. It is attached at a position facing the side outer periphery.

  As shown in FIG. 2, between the refrigerating room 2, the ice making room 3a, and the upper freezing room 3b, the refrigerating room 2 in the refrigerating temperature zone and the ice making room 3a and the upper freezing room 3b in the freezing temperature zone are partitioned and insulated. For this purpose, a partition heat insulation wall 12 is arranged. The partition heat insulating wall 12 is a heat insulating wall having a thickness of about 30 to 50 mm, and is made of a single material or a combination of a plurality of heat insulating materials such as styrofoam, foam heat insulating material (urethane foam), and vacuum heat insulating material.

Between the ice making chamber 3a and the upper freezing chamber 3b and the lower freezing chamber 4, since each of the chambers 3a, 3b and 4 is in the same freezing temperature zone, a partition which is not a partition heat insulating wall which partitions and insulates the chambers but a mere partition A member 13 is provided. A receiving surface 13 u of the packing 11 is formed on the front surface of the partition member 13.
A partition heat insulating wall 14 is provided between the lower freezer compartment 4 and the vegetable compartment 5 to insulate and heat the lower freezer compartment 4 in the freezing temperature zone and the vegetable compartment 5 in the refrigerated temperature zone. Similarly to the partition heat insulation wall 12, the partition heat insulation wall 14 is a heat insulation wall of about 30 to 50 mm, and is similarly made of styrofoam, foam heat insulation (urethane foam), vacuum heat insulation or the like.

Basically, partitions of rooms with different storage temperature zones such as refrigeration and freezing need to be insulated, and therefore, partition heat insulation walls 12 and 14 are installed.
The partition heat insulation walls 12 and 14 are each comprised with the expanded polystyrene 33 and the vacuum heat insulating material 50 (50d, 50e). The partition heat insulating walls 12 and 14 may be filled with a foam heat insulating material 23 such as rigid urethane foam, and are not particularly limited to the foamed polystyrene 33 and the vacuum heat insulating material 50.

In addition, in the box 1H, the storage compartments of the refrigerator compartment 2, the ice making compartment 3a and the upper freezer compartment 3b, the lower freezer compartment 4, and the vegetable compartment 5 are arranged from the top. Is not particularly limited to this.
The doors of the refrigerator compartment doors 6a and 6b, the ice making compartment door 7a, the upper freezer compartment door 7b, the lower freezer compartment door 8 and the vegetable compartment door 9 are also opened / closed by rotation, opened / closed by a drawer, and the number of divided doors. There is no particular limitation.

A box 1H that forms the main body of the refrigerator 1 includes an outer box 21 that forms an outer shell of the refrigerator 1 and an inner box 22 that forms a storage chamber.
The box 1H is provided with a heat insulating portion in a space formed between the outer box 21 and the inner box 22, and each storage room (2, 3a, 3b, 4, 5) in the box 1H and a refrigerator. 1 is insulated from the external space.
The vacuum heat insulating material 50 (50a, 50b, 50c) is arranged on the upper surface portion, the back surface (rear surface) portion, and the lower surface portion on either the outer box 21 side or the inner box 22 side, and in a space other than the vacuum heat insulating material 50. Is filled with a foam heat insulating material 23 such as rigid urethane foam.

  Moreover, in order to cool each room, such as the refrigerator compartment 2, the freezer compartment (3a, 3b, 4), the vegetable compartment 5, etc. of the refrigerator 1, to the predetermined temperature, the back side (rear side) of the freezer compartment (3a, 3b, 4) 2), as shown in FIG. 2, a cooler 28 for cooling the inside of the cabinet is provided. The refrigeration cycle is configured by connecting the cooler 28, the compressor 30, the condenser 31, and a capillary tube (not shown) and circulating the refrigerant. A blower 27 is disposed above the cooler 28, and the blower 27 circulates the cold air cooled by the cooler 28 inside the refrigerator 1 and maintains it at a predetermined low temperature.

  Moreover, the inside lamp | ramp 45 which has the case 45a which protruded in the foaming heat insulating material 23 side in a part of top | upper surface of the inner box 22 is arrange | positioned, and the refrigerator compartment door 6a, 6b of the refrigerator 1 is opened. Is bright and easy to see. The interior lamp 45 is not particularly limited, such as an LED (Light Emitting Diode), a light bulb, a fluorescent lamp, or a xenon lamp.

When the interior lamp 45 is disposed so as to protrude with respect to the foam heat insulating material 23, the thickness of the foam heat insulating material 23 between the case 45a and the top plate 21a1 of the outer box 21 becomes thin. Therefore, in the example of FIG. 2, the vacuum heat insulating material 50 a having high heat insulating properties is arranged between the case 45 a and the top plate 21 a 1 of the outer box 21 to ensure heat insulating performance.
The position of the interior light 45 is not limited to the illustrated position as long as the interior is bright and easily visible.

  In addition, a concave portion 40 for storing a board on which an electrical component 41 for controlling the operation of the refrigerator 1 or a power supply board is accommodated is provided on the upper rear side of the box 1H (upper right side of the refrigerator 1 shown in FIG. 2). Is formed. And the cover 42 is covered by the aspect which covers the board | substrate with which the electrical component 41 was mounted, and a power supply board | substrate.

  Here, since the recessed part 40 is arrange | positioned in the state where only the space which accommodates the electrical component 41 in the foam heat insulating material 23 side was depressed, in order to ensure heat insulation thickness, an internal volume will be sacrificed inevitably. On the other hand, if the capacity (internal volume) of the refrigerator 1 is further increased, the thickness of the foam heat insulating material 23 between the recess 40 and the inner box 22 is reduced (inconsistent relationship).

Therefore, in the example of FIG. 2, the heat insulating performance is ensured by disposing the vacuum heat insulating material 50b having high heat insulating properties on the surface of the foam heat insulating material 23 on the concave portion 40 side. In other words, the vacuum heat insulating material 50 b is disposed between the foam heat insulating material 23 and the electrical component 41.
The vacuum heat insulating material 50b is formed by bending (bending) the rear plate 21b along the recess 40 so as to match the shape of the recess 40.
In addition, since the compressor 30 and the condenser 31 arranged at the lower back of the box 1H (lower right of the refrigerator 1 in FIG. 2) are components that generate a large amount of heat, in order to prevent heat from entering the cabinet, A vacuum heat insulating material 50c is arranged on the projection surface from the compressor 30 or the condenser 31 to the inner box 22 side.

<< Embodiment 1 >>
The refrigerator 1 of Embodiment 1 of this invention is demonstrated.
3 is a cross-sectional view of the refrigerator in FIG. 2 taken along the line XX.
In the refrigerator 1 of the first embodiment, the outer box steel plate 21a that forms the outer box 21 of the box 1H is configured of the left and right side plates 21a2 and 21a3 and the top plate 21a1 of the refrigerator 1 with a single steel plate.
And the vacuum heat insulating material 50a is arrange | positioned on the inner surface (inner surface) of the outer box steel plate 21a along the shape of the outer box steel plate 21a. That is, the vacuum heat insulating material 50a is arranged in a continuous shape from the inner surface of the left side plate 21a2 of the outer box steel plate 21a to the inner surface of the top plate 21a1 and the inner surface of the right side plate 21a3.

  Although the vacuum heat insulating material 50a and the outer box steel plate 21a are arranged by adhesion using an adhesive type hot melt adhesive (not shown), a corner B portion in FIG. 3 which is a bent portion 21ao of the outer box steel plate 21a. (Non-adhesive portion 58a in FIG. 5B) was a non-adhesive portion without applying a hot melt adhesive. As an adhesive for fixing the vacuum heat insulating material 50a and the outer box steel plate 21a, an adhesive means other than the hot melt adhesive may be used.

Here, the vacuum heat insulating material 50 (50a, 50b, 50c, 50d, 50e) shown in FIG. 2 will be described with reference to FIG. FIG. 4 is a cross-sectional view showing the vacuum heat insulating material of the first embodiment. In FIG. 4, the adsorbent 54 is highlighted (exaggerated).
The vacuum heat insulating material 50 uses, as the core material 51, glass wool having an average fiber diameter of 4 μm, which is a laminate of inorganic fibers in which fibers are not bonded or bound together by a binder or the like. This glass wool is an aggregate of glass fibers obtained by laminating glass fibers in a layered manner so that a mass per unit area (hereinafter referred to as a basis weight) becomes a predetermined value by a centrifugal method. Since glass wool is not formed with a binder or the like, it is cotton-like and has a high bulk density.

  The inner bag 52 containing the core material 51 is not particularly limited as long as it is a synthetic resin film that can be heat-welded, but a high-density polyethylene film is used. In addition, although the high density polyethylene film is used as the inner bag 52, it may be a synthetic resin film that can be heat-welded, and is not limited to a high density, and may be a polyethylene film, a film of polypropylene, polybutylene terephthalate, or the like. .

The outer covering material 53 that covers the inner bag 52 and seals against the outer space is made of a multilayer laminate film having a predetermined gas barrier property, and has a property capable of being thermally welded together with the gas barrier property, There is no particular limitation as long as the predetermined degree of vacuum can be maintained.
As the covering material 53, a laminate film having a four-layer structure of a surface protective layer, a first gas barrier layer, a second gas barrier layer, and a heat welding layer was used.

As a specific configuration, the surface protective layer is a synthetic resin film such as polyamide, polypropylene, or polyethylene terephthalate, and a biaxially stretched film is preferable in consideration of gas barrier properties and moisture resistance.
As the first and second gas barrier layers, a biaxially stretched film provided with a gas barrier film made of metal, metal oxide, inorganic material or the like is preferable. For example, polyethylene terephthalate, ethylene vinyl alcohol copolymer, polyvinyl alcohol There are films such as. A metal foil layer may be provided on either one or both of the first and second gas barrier layers.

As the heat-welded layer, strength at the time of heat-welding is required, but for example, films such as polyethylene, polypropylene, polybutylene terephthalate, etc., such as low density, medium density, high density and linear low density are often used. .
The film of each layer is bonded by a dry laminating method through a two-component curable urethane adhesive, but the adhesive and the bonding method are not particularly limited thereto.
In addition, the laminate configuration of the jacket material 53 is not limited to a four-layer configuration, and three layers, five layers, or other plural layers may be used as long as the predetermined performance can be secured as a vacuum heat insulating material.

Further, as the adsorbent 54, a physical adsorption type synthetic zeolite that captures water molecules and gas molecules with fine pores was used. However, the adsorbent 54 is not particularly limited to this, and moisture or gas (at least oxygen O ₂ , nitrogen N ₂ , as long as it adsorbs carbon dioxide (CO ₂ ), either physical adsorption or chemical reaction type adsorption such as ion bonding may be used. However, it is not possible to use a material that is highly reactive and that alters the material constituting the vacuum heat insulating material 50 or generates a by-product.

Next, the manufacturing method of the refrigerator 1 is demonstrated using FIG. 5A-FIG. 5D.
5A to 5D are diagrams illustrating an example of a manufacturing process of the refrigerator according to the first embodiment.
First, as shown in FIG. 5A, the vacuum heat insulating material 50a is bent and formed into a U-shape so as to match the portal shape (see FIG. 5D) of the outer box steel plate 21a described later. At this time, the shape of the bent portion 58 of the vacuum heat insulating material 50a was made to be substantially convex inside the bent portion. The bent portion 58 of the vacuum heat insulating material 50a has a dimension longer than the length of the bent portion 21ao of the opposing outer box steel plate 21a.
The reason for this is that, as shown in FIGS. 5B to 5D, when the vacuum heat insulating material 50a is disposed on the outer box steel plate 21a, the dimension error in the dimension after bending the outer box steel sheet 21a and the dimension after bending of the vacuum heat insulating material 50a. Therefore, it is provided as a part that absorbs the dimensional error.

  The bent portion 58 of the vacuum heat insulating material 50a has a shape having a curvature as viewed from the front in FIG. 5A. In forming the bent portion 58, the vacuum heat insulating material 50a is gradually formed along a jig having a curved shape, for example, a round bar or a protruding jig like a round bar.

The shape of the bent portion 58 may be a shape having a corner that does not damage the outer covering material 53, such as a bellows-like corrugated shape, and is not limited. For example, a shape having a corner and a curvature may be used.
However, if the shape of the bent portion 58 is a shape having a curvature (for example, a circular cross section, an elliptical cross section, or other shapes having a curvature), it is difficult for stress concentration to occur and the jacket material 53 can be damaged. Most preferred because of its low nature.

  Then, as shown in FIG. 5B, the bent heat insulating material 50a is held using a dedicated jig (not shown) or equipment (not shown), and the top plate 50a1 of the vacuum heat insulating material 50a is held in the outer box steel plate 21a. Arranged on the top plate 21a1. At this time, the left and right side plates 21a2 and 21a3 of the outer box steel plate 21a are left slightly open.

  In addition, on the inner surface side of the outer box steel plate 21a, before the vacuum heat insulating material 50a is disposed, an adhesive type hot melt adhesive is applied in advance by a hot melt application device (not shown) except for the non-adhesive portion 58a. deep. An example of the hot melt coating apparatus is a roll coater. The roll coater adjusts the distance between the roll to which the hot melt adhesive is applied to a predetermined thickness and the steel plate 21a placed on the conveyor, and transfers and applies the hot melt adhesive on the roll to the inner surface of the steel plate 21a.

  Then, as shown in FIG. 5C, after the top plate 50a1 of the vacuum heat insulating material 50a is pressed and bonded to the top plate 21a1 of the outer box steel plate 21a, the left and right side plates 21a2 and 21a3 of the outer box steel plate 21a that are opened are attached. By closing, the left and right side plates 21a2 and 21a3 of the outer box steel plate 21a are bonded to the left and right side plates 50a2 and 50a3 of the vacuum heat insulating material 50a (see FIG. 5D).

  At this time, the bent portion 58 of the corner portion of the vacuum heat insulating material 50a is floated without being bonded to the steel plate 21, so that the dimensional error of the outer case steel plate 21a and the dimensional error of the vacuum heat insulating material 50a are absorbed and the shape does not match. To prevent. Moreover, the difference in curvature at the time of bending between the vacuum heat insulating material 50a and the outer box steel plate 21a is absorbed.

  That is, the non-bonded portion (folded portion 58) of the vacuum heat insulating material 50a has errors in the bending dimensions of the outer box steel plate 21a and the vacuum heat insulating material 50a, and each dimensional error due to the bending of the outer box steel plate 21a. Absorbs the tensile force caused by or processing. That is, by not bonding the substantially convex portion (the bent portion 58), it plays a role of so-called “play” in which the portion can freely move.

  Thus, since the load such as a tensile load acting on the jacket material 53 of the vacuum heat insulating material 50a can be absorbed, the vacuum heat insulating material 50a can be bent without difficulty along the bending of the outer box steel plate 21a. Therefore, the long-term reliability (long-term reliability) of the vacuum heat insulating material 50a can be maintained as in the case without bending.

  In addition, about the adhesion | attachment means used for adhesion | attachment with the outer box steel plate 21a and the vacuum heat insulating material 50a, it does not specifically limit to a hot-melt-adhesive, As long as the vacuum heat insulating material 50a can adhere | attach to the outer box steel plate 21a. Good. Further, an adhesive means may be provided on the vacuum heat insulating material 50a side, and this is not particularly limited.

The heat insulation performance of the box 1H of the refrigerator 1 of the first embodiment is measured as an amount of heat leakage from the box 1H, and the result is compared with the heat insulation performance of Comparative Examples 1 to 3 described later.
The amount of heat leakage of the refrigerator box was defined as follows.
The amount of heat leakage of the refrigerator box (unit: W) means that the heater is energized and heated in the refrigerator 1 in a room at a certain temperature, and each storage room temperature of the refrigerator 1 is stabilized at a set temperature. This is an index for confirming how much heat is leaking from the refrigerator 1.

In practice, the refrigerator 1 is installed in a temperature-controlled room set to a low temperature, and the difference between the temperature in each storage room and the room temperature is the same as the difference between each storage room temperature and room temperature during normal use of the refrigerator 1. Controls the heater and the internal fan installed inside. A value obtained by adding the heater input and the fan input when the temperature in each storage room is stabilized to a set value is defined as 100 (index) as a heat leakage amount.
That is, the amount of heat leakage of the refrigerator 1 described above is set as 100, and the amount of heat leakage is compared with the embodiments and comparative examples described later.

<< Embodiment 2 >>
6A and 6B are diagrams illustrating an example of a manufacturing process of the refrigerator according to the second embodiment.
In the first embodiment, the case where the outer box steel plate 21a and the vacuum heat insulating material 50a are combined after being bent is illustrated, but in the second embodiment, as shown in FIG. 6A, the flat state before the outer box steel plate 21a is bent. The vacuum heat insulating material 50a is arranged.

Two substantially convex portions 59 are provided in advance in the vacuum heat insulating material 50a. The substantially convex portion 59 has the same dimension absorbing portion role as the bent portion 58 of the dimension absorbing portion shown in the first embodiment.
In the vacuum heat insulating material 50a shown in FIG. 6A, the projection surface of the substantially convex portion 59 on the outer box steel plate 21a side (the projection surface in the vertical direction in FIG. 6A) is a non-adhesive portion, and on the bent portion 21ao of the outer box steel plate 21a. Placed in. The substantially convex portion 59 of the vacuum heat insulating material 50a has a dimension longer than the length of the bent portion 21ao of the opposed outer box steel plate 21a.

  The substantially convex portion 59 of the non-adhesive portion is a space in which a pressing jig (not shown) for pressing the inner side of the outer box steel plate 21a when the outer box steel plate 21a is bent is inserted in addition to the role of the dimension absorbing portion. However, a certain amount of space is required. If the pressing jig cannot be inserted, the outer shape of the bent portion of the outer box steel plate 21a is not neat.

The holding jig is a jig having a square-like shape for taking out the angle (about 90 degrees) of each bent portion 21ao between the top plate 21a1 of the outer box steel plate 21a and the left and right side plates 21a2, 21a3.
As a result of measuring the heat insulation performance of the box 1H of the refrigerator of the second embodiment as the amount of heat leakage from the box 1H, the refrigerator 1 of the second embodiment was also 100 with respect to 100 (index) of the first embodiment.

<< Embodiment 3 >>
In the first and second embodiments, the vacuum heat insulating material 50a is bonded to the inner surface of the top plate 21a1 and the left and right side plates 21a2 and 21a3 of the outer box steel plate 21a, and the top plate 21a1 and the left and right side plates 21a2 and 21a3 respectively. Although the case where the non-adhesive part 58a (refer FIG. 5B) is provided in a bending part was illustrated, in Embodiment 3, the vacuum heat insulating materials 150a and 250a (refer FIG. 7A and FIG. 8A) are each left and right side board of the outer case steel plate 21a. It adheres to the inner surfaces of 21a2 and 21a3 and is not adhered to the top plate 21a1 (see FIGS. 7B and 8B).

FIG. 7A and FIG. 7B are diagrams showing an example of a manufacturing process in which the vacuum heat insulating material of Embodiment 3 is bonded to the outer box steel plate after being bent into a U-shape so as to match the portal shape of the outer box steel plate. . FIG. 7B shows a cross-section with the upper half cut away.
In FIG. 7A, an adhesive is applied to the inner surfaces of the left and right side plates 21a2 and 21a3 of the outer box steel plate 21a or the outer surfaces of the left and right side plates 150a2 and 150a3 formed by bending from the top plate 150a1 of the vacuum heat insulating material 150a. ing.

  7A, the left and right side plates 21a2 and 21a3 of the outer box steel plate 21a are closed toward the left and right side plates 150a2 and 150a3 of the vacuum heat insulating material 150a, thereby the left and right sides of the outer box steel plate 21a. The face plates 21a2 and 21a3 are bonded to the left and right side plates 150a2 and 150a3 of the vacuum heat insulating material 150a.

  In this case, when the vacuum heat insulating material 150a is bonded to the outer box steel plate 21a, the top plate 150a1 of the vacuum heat insulating material 150a and the top plate 21a1 of the outer box steel plate 21a are not bonded to each other with a clearance c1. Is configured. Therefore, when the left and right side plates 150a2, 150a3 of the vacuum heat insulating material 150a are bonded to the left and right side plates 21a2, 21a of the outer box steel plate 21a, a load such as a tensile force is not applied to the vacuum heat insulating material 150a, It is suppressed that the long-term reliability (long-term reliability) of the vacuum heat insulating material 150a is impaired.

8A and 8B are diagrams illustrating an example of a manufacturing process in which the vacuum heat insulating material according to the third embodiment is disposed by adhering the vacuum heat insulating material in a flat state before the outer box steel plate is bent.
As shown in FIG. 8A, the vacuum heat insulating material 250a is formed into a shape in which the top plate 250a1 is located above the left and right side plates 250a2, 250a3, that is, a shape separated from the outer box steel plate 21a.

  An adhesive is applied to the inner surfaces of the left and right side plates 21a2 and 21a3 of the outer box steel plate 21a or the outer surfaces of the left and right side plates 250a2 and 250a3 of the vacuum heat insulating material 250a, and the inner surfaces of the left and right side plates 21a2 and 21a3 of the outer box steel plate 21a. Are bonded to the outer surfaces of the left and right side plates 250a2 and 250a3 of the vacuum heat insulating material 250a.

  8B, the left side plate 21a2 of the outer box steel plate 21a and the left side plate 250a2 of the vacuum heat insulating material 250a, the right side plate 21a3 of the outer box steel plate 21a and the right side plate 250a3 of the vacuum heat insulating material 250a, 8B is formed by bending the top plate 21a of the outer box steel plate 21a and the top plate 250a1 of the vacuum heat insulating material 250a.

In the state of FIG. 8B, the top plate 21a1 of the outer box steel plate 21a and the top plate 250a1 of the vacuum heat insulating material 250a are not bonded, and a clearance c2 is formed.
In this case, as shown in FIG. 8A, the top plate 250a1 of the vacuum heat insulating material 250a is formed longer than the length of the outer box steel plate 21a opposed to the top plate 250a1 of the vacuum heat insulating material 250a. An error, a dimensional error of the vacuum heat insulating material 250a, a difference in curvature between the bent portion of the outer casing steel plate 21a and the bent portion of the vacuum heat insulating material 250a at the time of bending as shown in FIG. 8B, and the like are absorbed.
Therefore, a load such as a tensile force is not applied to the vacuum heat insulating material 250a during the bending forming of FIG. 8B.
Therefore, it is suppressed that the long-term reliability (long-term reliability) of the vacuum heat insulating material 250a is impaired.

  According to the configurations of the first to third embodiments, the vacuum heat insulating material 50a (150a, 250a) is disposed across the left and right side plates 21a2, 21a3 and the top surface plate 21a1 of the refrigerator 1, so that the vacuum heat insulating material 50a (150a , 250a) can be increased. Therefore, the influence of the heat bridge due to the outer covering material 53 of the outer packaging material can be reduced, and the average thermal conductivity of the vacuum heat insulating material 50a (150a, 250a) itself can be lowered.

  Further, the area covered with the vacuum heat insulating material 50a (150a, 250a) can be increased, and the corner portion (folded portion 21ao) of the box 1H of the refrigerator 1 is also folded and arranged while maintaining the thickness of the core material 51. The heat insulation performance is good and the power consumption can be reduced.

Further, when the vacuum heat insulating material 50a (150a, 250a) is attached to the outer box steel plate 21a, the vacuum heat insulating material 50a (150a, 250a) is incorporated into the refrigerator 1 by providing an adhesive portion and a non-adhesive portion. In addition, it is possible to reduce a load such as a tensile force applied to the vacuum heat insulating material 50a (150a, 250a), and it is possible to suppress deterioration of reliability over a long period of time.
Therefore, it is possible to provide a refrigerator 1 with high performance reliability and to provide a refrigerator 1 with good assemblability in the manufacturing process.

(Comparative Example 1)
In Comparative Example 1, in the first embodiment, the shape of the bent portion 58 of the corner portion of the vacuum heat insulating material 50a is made flat without being substantially convex, and the vacuum heat insulating material 50a is viewed from the front (front) (see FIG. 5A). The vacuum heat insulating material 50a is arranged on the outer box steel plate 21a, except that the U-shape is the same.

As a result, the U-shaped dimension (width dimension when viewed from the front) of the vacuum heat insulating material 50a after bending is slightly negative (short), and the outer casing steel plate 21a The size and shape after bending did not match.
Due to this shape deviation, when the vacuum heat insulating material 50a and the steel plate 21a are bonded, the side plate portions on both sides of the vacuum heat insulating material 50a are pulled to the steel plate 21a side, and the jacket material 53 of the vacuum heat insulating material 50a. Was incorporated into the box 1H while being stretched.

On the contrary, the steel plate 21a is also pulled to the vacuum heat insulating material 50a side, and strain (waving distortion) is generated on the surface of the steel plate 21a. In addition, the plate | board thickness of the steel plate 21a is 4-5 mm in all of Embodiments 1-3 and Comparative Examples 1-3. The plate thickness of the steel plate 21a is an example, and it is needless to say that it is not limited.
As a result of measuring the heat insulation performance of the box 1H of the refrigerator 1 of Comparative Example 1 as the amount of heat leakage from the box 1H, the refrigerator of Comparative Example 1 was 100 compared to 100 (index) of Embodiment 1.
However, in Comparative Example 1, as described above, the outer cover material 53 of the vacuum heat insulating material 50a is incorporated in the box 1H while being stretched, and the surface of the steel plate 21a has a distortion (a wavy distortion). A problem that does not occur in the first to third embodiments occurs.

(Comparative Example 2)
In Comparative Example 2, in the second embodiment, the vacuum heat insulating material 50a is formed in a flat shape without providing the substantially convex portion (see FIG. 5B) of the bent portion 58 in advance, and the vacuum heat insulating material without providing a non-adhesive portion. Almost the entire surface of 50a was adhered to the outer box steel plate 21a.

  As a result, the left and right side plates 21a2, 21a3 and the top plate of the steel plate 21a serve as pressing jigs (square bar-like jigs) for bending the outer box steel plate 21a into the left and right side plates 21a2, 21a3 and the top plate 21a, respectively. It could not be inserted into the bent portion 21ao with 21a, and only a part inside the outer box steel plate 21a could be pressed. For this reason, the bent portions 21ao of the left and right side plates 21a2, 21a3 and the top plate 21a outside the outer box steel plate 21a are rounded and cannot be formed into a predetermined shape.

Further, since the entire surface of the vacuum heat insulating material 50a is bonded to the outer box steel plate 21a, the vacuum heat insulating material 50a is pulled by the outer case steel plate 21a in the bending direction when the outer case steel plate 21a is bent, and the outer covering material 53 is stretched. Occurred. It is estimated that the elongation of the jacket material 53 may cause a problem in terms of long-term reliability of the vacuum heat insulating material 50a.
As a result of measuring the heat insulation performance of the box 1H of the refrigerator 1 of the comparative example 2 as the amount of heat leakage from the box 1H, the refrigerator 1 of the comparative example 2 is a little as 101 (100) for the first embodiment (index). 1 point) It was getting worse.

In addition, since elongation occurred in the jacket material 53 of the vacuum heat insulating material 50a of Comparative Example 2, when the same measurement was performed after about one month to confirm the change with time, the amount of heat leakage was 102, Compared to the first embodiment, it was worse by 2 points. When the refrigerator 1 of Comparative Example 2 was disassembled and the vacuum heat insulating material 50a was examined, the aluminum vapor deposition layer in the portion where the covering material 53 was extended was thin, and was in a slow leak state (slow leak state). .
In addition, about Embodiment 1-3, and the comparative example 1 similarly, although the amount of box heat leaks after about one month was measured, the mode which was not getting worse was not seen.

(Comparative Example 3)
In Comparative Example 3, in Embodiment 1, the shape of the bent portion 58 of the corner portion of the vacuum heat insulating material 50a is not substantially convex (see FIG. 5B), and the groove is previously formed in the inner portion of the bent portion of the vacuum heat insulating material 50a. The vacuum heat insulating material 50a was arrange | positioned to the outer box steel plate 21a as it was the same except having made the U-shape after processing.

  As a result, since there is no “play” in the vacuum heat insulating material 50a (the bent portion 58 in FIG. 5A in Embodiment 1 and the substantially convex portion 59 in FIG. 6B in Embodiment 2), each of the vacuum heat insulating material 50a and the outer box steel plate 21a. Although the shapes did not match slightly due to the dimensional error, when both were pasted as they were, a gap was formed in the groove of the bent portion 21ao of the outer box steel plate 21a.

As a result of measuring the heat insulation performance of the box 1H of the refrigerator 1 of the comparative example 3 as the amount of heat leakage from the box 1H, the refrigerator 1 of the comparative example 3 is 102 with respect to 100 (index) of the first embodiment. 2 points worsened.
This is thought to be because the heat leakage amount deteriorated due to the decrease in the heat insulation thickness due to the groove processing provided in the bent portion 58 of the vacuum heat insulating material 50a.
As described above, in Comparative Examples 1 to 3, it is clear that all of the problems that are not found in Embodiments 1 to 3 occur or the amount of heat leakage is large, and the performance deteriorates compared to the configurations of Embodiments 1 to 3. became.

<< Other Embodiments >>
In the first and second embodiments, the case where the top plate 21a1 and the left and right side plates 21a2, 21a3 are formed of one steel plate is illustrated. However, the top plate 21a1 and the left / right side plates 21a2, 21a3 are You may comprise with several steel plates. For example, the top plate 21a1 and the left and right side plates 21a2, 21a3 may be formed by welding a plurality of steel plates by thermite welding, arc welding, or the like, or connecting them with screws.

  Further, in the first and second embodiments, the case where the space between the outer box 21 and the inner box 22 is filled with the foam heat insulating material 23 is exemplified. A heat insulating material other than the foamed heat insulating material 23 such as a fiber may be used.

In the first and second embodiments, the case where the steel plate is formed by bending the flat plate into the top plate 21a1 and the left / right side plates 21a2, 21a3 is exemplified. However, the flat plate is the top plate 21a1 and the left / right side plates 21a2. , 21a3, but can be selected as appropriate.
For example, the steel plate is formed by bending the flat plate on the top plate 21a1 and the left side plate 21a2, the steel plate is formed by bending the flat plate on the top right side plate 21a3 and the bottom plate 21e (see FIG. 2), or the steel plate is formed of the flat plate. The rear plate 21b and the left and right side plates 21a2 and 21a3 may be bent and formed.

In the first and second embodiments, the case where the outer plate 21 forming the outline of the refrigerator 1 is formed of a steel plate is exemplified. However, various properties necessary for the outer plate 21 such as predetermined strength and predetermined thermal conductivity. If obtained, the outer plate 21 may be configured using a plate material (material) other than a steel plate.
In the first and second embodiments, the refrigerator 1 including the freezer compartments (3a, 3b, 4) and the refrigerator compartments (2, 5) has been described as an example. However, the refrigerator comprising the refrigerator compartment in the refrigerator temperature zone. In addition, the present invention is applicable. Moreover, the present invention can be effectively applied to a freezer that is not limited to a refrigerator and includes a freezing room in a freezing temperature zone.

1 Refrigerator 2 Cold room (storage room)
3a Ice making room (storage room)
3b Upper freezer room (storage room)
4 Lower freezer compartment (storage room 5 vegetable room (storage room)
21 Outer box 21a Steel plate 21a1 Top plate (flat plate)
21a2 Left side plate (plane plate, side plate)
21a3 Right side plate (plane plate, side plate)
21ao folded part (folded part)
21b Rear plate (flat plate)
21e Bottom plate (flat plate)
22 Inner box 23 Foam insulation (heat insulation)
27 Blower 50, 50a Vacuum heat insulating material 51 Core material 58 Bent part (non-adhesive part)
59 Convex (non-adhesive)
150a1, 250a1 Top plate (non-bonded part)

Claims (3)

A refrigerator including a heat insulating material and a vacuum heat insulating material between an outer box forming an outer shell and an inner box forming a storage chamber,
The outer box is formed to include a plate material formed into a shape in which a plurality of flat plates are bent at a bending portion ,
On the surface on the inner box side of the plate material, a place with a core material of the vacuum heat insulating material is disposed so as to straddle the plurality of flat plates,
The vacuum heat insulating material is disposed on the plate of the outer box by bonding and a non-bonding portion is provided in the vicinity of the bent portion ,
The non-adhered part of the vacuum heat insulating material is formed longer than the length of the non-adhered part of the plate material facing the non-adhered part . The refrigerator according to claim 1, non-adhesive portion of the vacuum heat insulating material, characterized in that convexly curved are disposed in said box-side. The vacuum heat insulating material disposed along the inner side surface of the plate of the outer box constituting the outer plate and the side plate forming the outer shell of the refrigerator is bonded to the side plate and the portion facing the top plate is A method for manufacturing a refrigerator, wherein the refrigerator is formed longer than the top plate and is not bonded to the top plate, and a clearance is formed between the vacuum heat insulating material and the top plate .

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