Method for constructing a bent-edged plastic door for a household electrical appliance, in particular a refrigerator, and the door obtained in this manner

Abstract: A method for constructing a plastic door (1) for a household electrical appliance, in particular a refrigerator, said door (1) comprising an outer shell (2) with which a door liner (3) is associated, at least said shell (2) or outer part being obtained by usual forming methods such as vacuum-forming or pressing; following its forming, the edge (5) of said outer part (2) is bent towards the inner cavity of this latter, said bending being implemented while maintaining said part or shell (2) in a locked state and acting on that portion thereof in proximity to its free edge. A door (1) obtained by the aforesaid method comprises a shell (2) with its edge (5) bent towards its interior (6) and a door liner (3) housed on said shell (2), the bent continuous edge (5) of this latter being exposed to view.

Description: This invention relates to a method for constructing a plastic door for a household electrical appliance, in particular a refrigerator, in accordance with the introductory part of the main claim. The invention also relates to a door obtained in this manner. As is well known, each refrigerator door, for example of a multi-compartment upright refrigerator, comprises a shell or outer part with which a door liner is associated. Usual insulating material is provided between the two parts. The door liner can comprise support shoulders for shelves to hold foods and food containers. A usual seal element is provided along the liner edge. The door shell and liner are produced by usual forming methods such as vacuum-forming or by pressing (moulding). After they have been formed they are joined together and insulating material such as polyethylene is inserted (injected) between them. The shell also supports usual junction pieces carrying the hinges or comprising seats for these latter. The known method for producing a plastic door for a refrigerator generally results in a door being obtained having sharp edges. The joints between the shell and liner can often be seen along these edges. This obviously has a negative effect on the appearance of the product. US patent 5716581 describes a method for thermoforming a plastic refrigerator door of the aforesaid type. According to this known method a shell is formed with an annular flange facing the shell interior to receive the edge of a liner. In this respect, after the door liner has been thermoformed, a plastic sheet is laid on it and is itself thermoformed to form the shell. As soon as this has been completed the shell and liner are fitted together and heat is applied along their contacting edges to join them together by fusion'of the parts. After the shell and liner have been joined together their end edges are cut off. This thus implies a final product which always has sharp edged lateral parts, and in which the shell and liner edges are recognizable. Consequently, the invention of this US patent again results in a product which is not of perfect appearance. US patent 3 634 971 discloses a refrigerator door in which the front panel is injection molded to include an integral, channel-shaped side that has an inside leg, a side surface and a front leg. US patent 2 837 186 discloses a front panel of a refrigerator door made by sheet metal and having cup-shaped edges inwardly flanged. An object of the invention is to provide an improved method for producing a thermoformed plastic door, by which the door is of attractive appearance. A further object is to provide a method of the aforesaid type which is of reliable implementation and offers a product of constant results. A further object is to provide a door produced by the aforesaid method which is of attractive appearance and does not present junction lines between the shell and liner along its lateral edges. A further object is to provide a method which enables refrigerator doors to be produced which do not have to be subjected to final painting and which therefore enables doors to be obtained at lower cost than the doors produced by known methods. These and further objects which will be apparent to the expert of the art are attained by a method and by a door produced by this method, in accordance with the accompanying claims. The invention will be more apparent from the accompanying drawing, which is provided by way of non-limiting example and on which: Figure 1 is an exploded perspective view of a shell for a refrigerator door obtained in accordance with the invention; Figure 2 is a perspective view of a door obtained in accordance with the invention; Figure 3 is a section on the line 3-3 of Figure 1; Figure 4 is a schematic cross-section through a device for implementing the method of the invention; and Figure 5 is a partial perspective view of part of the device of the invention. With reference to Figures 1 to 3, a plastic refrigerator door is indicated overall by 1 and comprises a shell 2 and a door liner 3 fixed to this shell by known methods. The shell comprises a body 4 of thermoplastic material having its continuous edge 5 bent towards the interior 6 of the body 4, which is for example of concave dished shape. Elongate elements can be secured to the upper and lower opposing ends of the body 4 to define so-called junction pieces 4A (only one of which is visible in Figure 1) with which usual hinge members are associated for moving the door relative to the refrigerator housing (not shown). With the body 4 there is also associated a substantially U-shaped stiffening element 7 fixed in any known manner (eg. mechanically by hot deformation) between opposing long sides 10 and 11 of said body. These are connected to short sides 10A and 11A. The door liner 3 is fixed in known manner to the body 4, and comprises shoulders 3A and shelves 3B which are supported by support elements 3B either fixed to or formed within said shoulders. According to the invention, the edge 5 of the body 4 is smoothly bent to define substantially a perimetral flange 5A extending towards the inner cavity 6 of this body. By this means, when the door 1 is assembled (and provided with a usual peripheral gasket 12 positioned around the door liner 3), on the inside of the door a perimetral surface can be seen which blends into its lateral wall 8 and rear wall 9 without discontinuity, so giving the finished article (refrigerator) a particularly attractive appearance. The door 1 is obtained by the method of the invention. According to this (see Figures 4 and 5 in particular, in which parts corresponding to those of the already described figures are indicated by the same reference numerals), the door shell 2 is initially obtained by conventional forming methods such as vacuum-forming or moulding. This is done within a usual mould. After being prepared in this manner, the shell is subjected to a finishing operation on the edge to remove from it (and from any other part of the body 4) any burrs which may have been produced during forming. The body 4 is finished to the required dimensions for the next step of the construction process in which the edges of the shell 2 (of substantially U cross-section) are bent to form the flange 5 extending towards its inner cavity 6, without parts being mutually superposed. This is achieved within the actual forming mould (within its "female" part) or in another female mould 20 (see Figure 4) in which the shell 2 is placed following its formation. In this latter case the mould is treated internally such as to present a perfectly smooth surface free of impurities which could scratch the outer surface of the shell or become fixed to it. When in the mould 20, the shell 2 has its edge projecting from it. A counteracting member 21, for example associated with an actuator positioned above the mould 20 and movable vertically relative to the mould, is then inserted into the mould 20. As will be apparent to the expert of the art, this member comprises several parts 21A (only two are visible in Figure 4) movable towards the walls of the mould 20, and for this purpose are associated with an actuator 218 carried by the member 21. The edge 5 of the shell 2, projecting from the mould, is then heated by heating members such as hot air generators, usual electrical heaters, halogen lamps or the like. When the material of the edge 5 has reached a temperature at which it becomes soft and deformable (depending on the material itself), a plurality of forming members 25, driven by respective actuator members 26 and distributed along the perimeter of the mould 20, are moved towards and into contact with the edge 5 to urge it towards the inner cavity 6 of the shell body 4. This edge is hence bent at 90° to the shell sides 8. The forming members 25 can comprise a plurality of elements 29 (see Figure 5) moved along a plane perpendicular to the sides 8 defined by appropriate guides provided on the peripheral edge 20A of the mould 20. These elements are positioned for example along the sides 10, 10A, 11 and 11A of the body 4 and at its corners 5E. The elements 29 slide along those elements 29 adjacent to them to uniformly bend the edge 5 onto the counteracting member 21 even at the corners, without creating creases along the edge or on portions thereof which become superposed or lift up. The elements 29 are driven by the actuators 26, for example hydraulic. These elements are preferably wedge shaped, with their apex facing the edge 5, so as to form the flange 5A without them digging into the edge. The elements 29 are preferably coated with self-lubricating material, such as that known commercially as Teflon, to prevent the plastic surface of the shell edge 2 undergoing any damage or scraping effect. After the bending, the elements 29 are withdrawn from the shell edge, as are the movable members 21A of the counteracting member which hence rises from the mould, to allow extraction of the shell body 4 with its edges bent towards its interior 6. At this point the shell 2 is provided with each junction piece 4A. As stated, this latter supports the hinge for the movement of the door 1 relative to the refrigerator housing (not shown). The hinge (not shown) is for example of known type comprising a hinge arm fixed to the refrigerator housing, to be engaged with the seat provided in the junction piece on the door 1. A threaded pin is engaged with the thread provided in the hinge arm, said pin also engaging a bush rigid with the door 1 to enable this latter to be moved abut the hinge formed in this manner. Alternatively, the threaded pin and the bush on the door can be replaced by a suitably shaped injection-moulded box 40 which is premounted directly on the arm by push-insertion and is able to rotate about the hinge arm on the same axis of rotation as the door. This box is then push-inserted into a seat provided on the door junction piece 4A by means of reacting fins or teeth, not shown (this making it possible to extract the box from the door if its direction of opening is to be reversed). On terminating said operation, the door line 3 is associated with the shell 2 in known manner. In a variant of the aforesaid method, the edge 5 of the shell 2 can be-bent by one or more rollers running along this edge or by forming elements rotating about a hinge mounted on the edge 20A of the mould 20 and arranged to bend said edge towards the interior of the shell body 4. The invention also offers a modular system for constructing a refrigerator door, the system comprising elements which can be inserted or removed at successive times, depending on requirements.

Claims: A method for constructing a door (1) for a household electrical appliance, in particular a refrigerator, said door being of plastic and comprising a shell or outer part (2), at least said shell(2) being obtained by known forming methods such as vacuum-forming or pressing, characterised in that an inner door liner (3) is associated with said shell or outer part and in that , following the forming step, the edge of said shell (2) is deformed and bent towards the interior (6) of this latter, said bending being implemented along the entire perimetral edge of said shell. A method as claimed in claim 1, characterised in that the perimetral edge (5) of the shell (2) is bent while maintaining this latter within the forming mould. A method as claimed in claim 1, characterised in that after the shell (2) has been formed it is removed from the forming mould and is transferred to another mould wherein its perimetral edge (5) is bent. A method as claimed in claims 1 and 2 or 1 and 3, characterised by heating the edge (5) of the shell (2) before bending it, said edge projecting from the mould (20) in which said shell is contained. A method as claimed in claim 1, characterised in that the edge (5) is bent by thrusting each portion present along the sides (10, 10A, 11, 11A) of the shell towards the interior (6) of this latter, said urging taking place simultaneously and continuously on all said portions. A method as claimed in claim 1, characterised in that the edge (5) is bent by urging the edge portions present along the sides (10, 10A, 11, 11A) of the shell towards the shell interior (6) in succession. A method as claimed in claim 1, characterised in that after the peripheral edge (5) of the shell has been bent, there is associated with this latter at least one element forming an junction piece (4A) on the door. A method as claimed in claim 1, characterised in that a stiffening element (7) is associated with the shell (1) after its perimetral edge (5) has been bent. A method as claimed in claim 1, characterised in that the door liner is secured to the door after the junction piece (4A) and the stiffening element have been fitted. A refrigerator door obtainable by the method of claim 1, said door (1) comprising a plastic shell or outer part (2) , along the sides of said door (1) there being positioned a usual insulating gasket, said sides coinciding with the sides (10, 10A, 11, 11a) of the shell (2), characterised in that there is associated a door liner (3) provided with shelves or similar members (3B) for supporting foods or their containers with said shell or outer part, and in that the sides (10, 10A, 11, 11A) comprise an end portion (5A) bent towards the door liner (3) along the entire perimetrical edge of said shell (2), said end portion blending without discontinuity into the sides (8) of the shell and hence into the shell rear wall (9).

Inventors: MARITAN MARCO, SIGNA MARCO, MARITAN, MARCO, SIGNA, MARCO, Maritan, Marco, c/o Whirlpool Europe Pat.Dep., Signa, Marco, c/o Whirlpool Europe Pat.Dep.
Applicants: WHIRLPOOL CO, WHIRLPOOL CORPORATION
Application year: 1999
Main classification: B29C53
IPC codes: B29C53, B29C57, F25D23, B29C69