A METHOD FOR MAKING A COOLING DEVICE

Description

[0001] The present invention relates to a method of making a cooling device comprising a cover whereof the side facing the fresh food compartment is insulated.

[0002] In cooling devices, there are at least two compartments, generally one being a fresh food and the other a freezer, which are kept at different temperatures from each other. The fresh food compartment is allocated for storing foods such as fruits and vegetables and the temperature is kept around 5°C. In the freezer compartment, with a temperature around -18°C, foods such as meat and fish are placed that have to be stored for a longer time.

[0003] Foods of various types placed particularly in the fresh food compartment and the opening, closing of the fresh food and freezer compartment doors during the course of the day affect the humidity value of the air circulating in the compartment. In order to remove the moisture from air, the evaporator in the freezer compartment, forming the coldest place of the cooling device, is used. The evaporator maintains to cool the hot air aspirated from the fresh food compartment and at the same time to hold the moisture contained in the hot air.

[0004] In this type of cooling devices, an air channel is provided with air blowing holes arranged thereon, for conveying the air activated by the fan into the fresh food compartment. Thermostats for adjusting the temperatures of the fresh food and freezer compartments and a valve for controlling the air flow by changing the cross section of the air channel are disposed inside the air channel. The valve and the thermostat are situated inside the air channel and safeguarded by a cover. The cover separates the air channel and the fresh food compartment and a knob is placed thereon so that the user can adjust the valve and/or the thermostat from inside the fresh food compartment.

[0005] In state of the art embodiments, the insulation of particularly the cover that houses the damper thermostat is tried to be accomplished by applying styrofoam material on the inner wall. However, it is not possible to entirely adhere the styrofoam material on the inner wall of the damper thermostat cover that having particularly intended surfaces, a desired configuration without any gap therebetween itself and the surface. When a gap remains between the styrofoam material and the cover surface, cold air seeps into these gaps. Accordingly, condensation appears on the cover surface, particularly on the side facing the fresh food compartment, since the side of the cover facing the air channel is in contact with cold air and the side facing the fresh food compartment is in contact with relatively hotter air. In order to prevent this, a heater is disposed in contact with the surface of the cover facing the air channel. In this implementation, disposing styrofoam and heater on the cover increases both labor and costs and also the energy consumption.

[0006] In the state of the art Japanese Patent Applications No JP4359779 and JP10176880, refrigerators are explained wherein the switching chambers are insulated.

[0007] AU452338 B2 discloses the use of expanded polyurethane insulation slabs in a housing of an evaporator. The polyurethane insulation slabs are enclosed by outer moulded fibreglass casings.

[0008] EP0982553 A2 discloses a refrigerator having a housing installed at the centre of the rear wall of an refrigeration compartment, wherein a guide path is formed in the upper end of the housing for guiding cool air produced from an evaporator into the refrigeration compartment. A damper for controlling the amount of cool air provided to the refrigeration compartment by opening/closing the guide path and a damper motor for driving the damper are built in the upper end of the housing. Temperature in the refrigeration compartment is controlled by using these constituents in a conventional manner. A damper cover is incorporated in a front plate of the embodiment and a spacer is formed of an insulation material. The spacer is made thick to prevent condensation on the damper cover which results from a large amount of cool air passing through guide path.

[0009] DE4420149 A1 discloses a refrigerating system having an isolating panel with integrated cooling elements. A cover plate for an evaporator bears a fan. The cover plate is comprised of an isolating body enclosed by metal or plastics material. The isolating body helps avoiding condensation at the rear surface of the cover plate (with regard to evaporator).

[0010] US3280583 A discloses the use of an insulating evaporator housing in a refrigerator wherein for thermal insulation, a foamed polystyrene is foreseen. Alternatively, there might be polyurethane foam in which the foam cells are filled with a gas having a higher insulation value than air.

[0011] The aim of the present invention is the realization of a method for making a cooling device comprising a cover wherein condensation is prevented on the surface thereof facing the fresh food compartment.

[0012] The method for making a cooling device realized in order to attain the aim of the present invention is explicated in the claim. The cooling device comprises a cover, fitted over the air channel in the fresh food compartment, the surface thereof facing inside the air channel is entirely clad by polyurethane material, safeguarding the thermostat and the shutter disposed in the air channel, and a knob mounted thereon for controlling the thermostat and the shutter.

[0013] Thus, the surface of the cover, forming an intermediate surface where the cold and hot air meet, facing inside the air channel, is insulated such that no gap is left therebetween the insulation material and the surface wall. The polyurethane material, due to its feature, takes the shape of the mould and hence the shape of the cover by expanding and solidifying inside the mould and adheres to the surface of the cover facing the air channel without any gaps therebetween.

[0014] By means of the present invention, the surface of the cover, having surfaces forming intermediate surfaces where cold air and hot air meet inside the compartment, safeguarding for example the damper thermostat disposed inside the air channel, is effectively insulated. As a result, the use of a heater is not necessary, maintaining savings in cost, labor, and energy.

[0015] A cooling device realized by the method attaining the aim of the present invention is illustrated in the attached figures, where:

Figure 1 - is the front view of a cooling device.

Figure 2 - is the A-A cross sectional view of Figure 1.

[0016] The elements illustrated in the figures are numbered as follows:

1. Cooling device

2. Freezer compartment

3. Fresh food compartment

4. Evaporator

5. Fan

6. Cover

7. Air channel

8. Knob

9. Shutter

10. Thermostat

[0017] The cooling device (1) produced according to the method of the present invention comprises a freezer compartment (2) wherein foods to be frozen are placed, a fresh food compartment (3), kept at a higher temperature than the freezer compartment (2), wherein foodstuffs to be cooled are emplaced, at least one evaporator (4) for cooling the air circulated in the compartments (2, 3) one or more fans (5) for activating the air cooled by the evaporator (4), an air channel (7) for delivering the air activated by the fan (5) into the fresh food compartment (3), one or more thermostats (10) disposed inside the air channel (7) for regulating the temperatures of the compartments (2, 3), a shutter (9) that controls the air flow by changing the cross section of the air channel (7), a cover (6) that safeguards the shutter (9) and the thermostat (10), fitted over the air channel (7) in the fresh food compartment (3), such that one side faces the air channel (7) and the other side the fresh food compartment (3), and a knob (8) mounted on the cover (6) so that the user can adjust the shutter (9) and/or the thermostat (10) from inside the fresh food compartment (3).

[0018] The surface of the cover (6) facing the air channel (7) and in contact with the cold air passing through the air channel (7) is clad by polyurethane material, taking the shape of the said surface and without a gap between itself and the said surface (Figure 1 and Figure 2).

[0019] While the polyurethane material cladding is made, the side of the cover (6) that will face inside the fresh food compartment (3) is placed on the mould. The polyurethane material is poured on the inner wall of this surface and the mould is closed. The polyurethane material takes the shape of the mould and hence the shape of the cover (6) surface by expanding and solidifying inside the mould. This process prevents any gap remaining between the polyurethane material used as insulation material and the cover (6) surface. Any formation of condensation on the cover (6) surface is prevented since the heat insulation of polyurethane material is better and since there isn't any gap left between the polyurethane material and the cover (6) surface. Because the contact of cold air with the surface of the cover (6) facing the air channel (7) is prevented. Accordingly, the formation of condensation on the surface of the cover (6) facing inside of the fresh food compartment (3) and contacting with relatively hotter air is prevented. Besides, the polyurethane material adheres on the cover (6), preferably made of plastic, by itself. The use of a heater for preventing condensation is not necessary since the polyurethane material adheres to the cover (6) surface and entirely takes the shape of the surface. Furthermore, mounting the polyurethane material on the surface does not require additional time and labor consumption.

[0020] In another embodiment, the thermostat (10) is a damper thermostat and directly controls the shutter (9) that changes the cross section of the air channel (7).

[0021] In the present invention, the cover (6) is produced from polyurethane material. Thus, the side of the cover (6) facing inside the air channel (7) is made directly from polyurethane material. In this embodiment, polyurethane material is poured into the mould and the mould is closed. The polyurethane material taking the shape of the mould and hence the shape of the cover (6) by expanding and solidifying inside the mould is taken out and is mounted over the air channel (7) in the fresh food compartment (3).

[0022] In yet another embodiment of the present invention, the outer surface of the polyurethane material taken out of the mould is painted. In this embodiment of the present invention, the surface of the mould is painted in any color desired. Afterwards, polyurethane material is poured into the mould and the mould is closed. The polyurethane material taking the shape of the mould and hence the shape of the cover (6) by expanding and solidifying inside the mould is taken out with the side facing the fresh food compartment (3) painted. By painting the surface of the mould and this paint painting the outer surface of the polyurethane provides a smoother appearance.

[0023] By means of the present invention, the cover (6) that is subsequently mounted on the air channel (7) in the fresh food compartment (3), and having particularly indented surfaces, is insulated without any gaps between the polyurethane material and the cover (6) as a result of cladding the side thereof facing the air channel (7) by polyurethane material. Accordingly, formation of condensation on the cover (6) surface facing the fresh food compartment (3) is prevented. This removes the necessity of heater usage thereby maintaining savings in cost, labor, and energy.

Claims

1. A method for making a cooling device (1), the cooling device comprising a freezer compartment (2) wherein foods to be frozen are placed,
a fresh food compartment (3), kept at a higher temperature than the freezer compartment (2), wherein foodstuffs to be cooled are emplaced,
at least one evaporator (4) for cooling the air circulated in the compartments (2, 3), one or more fans (5) for activating the air cooled by the evaporator (4),
an air channel (7) for delivering the air activated by the fan (5) into the fresh food compartment (3),
one or more thermostats (10) disposed inside the air channel (7) for regulating the temperatures of the compartments (2, 3),
a shutter (9) that controls the air flow by changing the cross section of the air channel (7),
a cover (6) that safeguards the shutter (9) and the thermostat (10), wherein the cover (6) is fitted over the air channel (7) in the fresh food compartment (3), such that one side of the cover (6) faces the air channel (7) and the other side of the cover (6) faces the fresh food compartment (3), wherein the cover (6) has a surface facing the air channel (7) and in contact with the cold air passing through the air channel (7) and clad by polyurethane material, wherein the polyurethane material takes the shape of the said surface without leaving a gap between the polyurethane material and the said surface and
a knob (8) mounted on the cover (6) so that the user can adjust the shutter (9) and the thermostat (10),
the method comprising the steps of

- placing the surface of the cover (6) that will face inside the fresh food compartment (3) on a mould,

- pouring the polyurethane material on the inner wall of this surface,

- closing the mould such that the polyurethane material takes the shape of the mould and hence the shape of the cover (6) surface by expanding and solidifying inside the mould.

Ansprüche

1. Verfahren zum Herstellen einer Kühlvorrichtung (1), wobei die Kühlvorrichtung Folgendes umfasst
ein Gefrierfach (2), in das einzufrierende Lebensmittel gelegt werden,
ein Frischhaltefach (3), das auf einer höheren Temperatur als das Gefrierfach (2) gehalten wird und in das zu kühlende Lebensmittel gelegt werden,
wenigstens einen Verdampfer (4) zum Kühlen der Luft, die in den Fächern (2, 3) zirkuliert, ein oder mehrere Gebläse (5) zum Aktivieren der vom Verdampfer (4) gekühlten Luft,
einen Luftkanal (7) zum Leiten der durch das Gebläse (5) aktivierten Luft in das Frischhaltefach (3),
ein oder mehrere Thermostate (10), die im Inneren des Luftkanals (7) angeordnet sind, um die Temperaturen der Fächer (2, 3) zu regulieren,
einen Verschluss (9), der den Luftstrom durch Ändern des Querschnitts des Luftkanals (7) steuert,
eine Abdeckung (6), die den Verschluss (9) und das Thermostat (10) schützt, wobei die Abdeckung (6) über den Luftkanal (7) im Frischhaltefach (3) gesetzt ist, derart, dass eine Seite der Abdeckung (6) dem Luftkanal (7) zugewandt ist und die andere Seite der Abdeckung (6) dem Frischhaltefach (3) zugewandt ist, wobei die Abdeckung (6) eine Fläche aufweist, die dem Luftkanal (7) zugewandt ist und in Kontakt mit der kalten Luft steht, die durch den Luftkanal (7) strömt, und mit Polyurethanmaterial verkleidet ist, wobei das Polyurethanmaterial die Form der Fläche annimmt, ohne einen Spalt zwischen dem Polyurethanmaterial und der Fläche zu belassen, und
einen Knopf (8), der an der Abdeckung (6) angebracht ist, so dass der Benutzer den Verschluss (9) und das Thermostat (10) einstellen kann,
wobei das Verfahren folgende Schritte umfasst

- Anordnen der Fläche der Abdeckung (6), die dem Inneren des Frischhaltefachs (3) zugewandt ist, auf einer Gussform,

- Gießen des Polyurethanmaterials auf die Innenwand dieser Fläche,

- Schließen der Form, derart, dass das Polyurethanmaterial die Form der Gussform und damit die Form der Fläche der Abdeckung (6) annimmt, indem es sich in der Gussform ausdehnt und erhärtet.

Revendications

1. Un procédé de fabrication d'un dispositif de refroidissement (1), le dispositif de refroidissement comprenant
un compartiment de congélation (2) dans lequel les aliments à congeler sont placés, un compartiment d'aliments frais (3) qui est maintenu à une température supérieure par rapport au compartiment de congélation (2), dans lequel les aliments à refroidir sont placés,
au moins un évaporateur (4) pour refroidir l'air en circulation dans les compartiments (2, 3), un ou plusieurs ventilateurs (5) pour remuer l'air refroidi par l'évaporateur (4),
un canal d'air (7) pour délivrer l'air remué par le ventilateur (5) dans le compartiment d'aliments frais (3),
un ou plusieurs thermostats (10) qui sont disposés dans le canal d'air (7) pour régler les températures des compartiments (2, 3),
un volet (9) qui contrôle l'écoulement d'air en changeant la section transversale du canal d'air (7),
un couvercle (6) qui protège le volet (9) et le thermostat (10), où le couvercle (6) est monté sur le canal d'air (7) dans le compartiment d'aliments frais (3), de telle sorte qu'un côté du couvercle (6) fait face au canal d'air (7) et l'autre côté du couvercle (6) fait face au compartiment d'aliments frais (3), où le couvercle (6) présente une surface faisant face au canal d'air (7) et en contact avec l'air froid passant à travers le canal d'air (7) et recouverte par un matériau de polyuréthane, où le matériau de polyuréthane prend la forme de ladite surface sans laisser un espace entre le matériau de polyuréthane et ladite surface et
Un bouton rotatif (8) qui est monté sur le couvercle (6) de telle sorte que l'utilisateur peut ajuster le volet (9) et le thermostat (10),
le procédé comprenant les étapes de

- placer la surface du couvercle (6) qui fait face à l'intérieur du compartiment d'aliments frais (3) sur un moule,

Verser le matériau de polyuréthane sur la paroi intérieure de cette surface,

- fermer le moule de telle sorte que le matériau de polyuréthane prend la forme du moule et donc, la forme de la surface du couvercle (6) par l'expansion et la solidification dans le moule.

Drawing