Patent Description:
Usually, a foaming material of a door is polyurethane, and a foaming process is divided into <NUM> stages: a cream time stage, a gelation stage, and a curing stage. In addition, after foaming, air inside the door needs to be discharged. For example, the Chinese utility model patent <CIT> discloses a door for a refrigerating device, comprising a door front panel and a door liner opposed to each other, and door end covers between the door front panel and the door liner, wherein a cavity for injecting the foaming material is formed between the door front panel, the door liner and the door end covers; a material-injecting hole is disposed on one of the door end covers opposed to each other, and an air discharge hole adapted for inserting an air discharge pipe is disposed on the other of the door end covers; during air discharge, the foaming material in the gelation state will be discharged through the air discharge hole out of the door end covers and needs to be manually cleaned. As such, not only the man power is wasted and the manufacturing cost is increased, but also the foaming material cannot be cleaned thoroughly, thereby affecting the quality of the products of the door.

<CIT> discloses a heat-insulating wall constructed from individual layers arranged one above the other, wherein the layer which contributes to the heat insulation is arranged between exterior covering layers, enclosing an inner space. A heat insulation material can be introduced, in the form of liquid starting components, into the inner space via an opening. The air displaced by the heat insulation can escape via at least one outlet opening which is equipped with means preventing the heat-insulation material from escaping.

<CIT> discloses a venting device for refrigerators or freezers, which comprises a sheath and a sleeve. Between the sheath and the sleeve there are constituted at least one zone of compaction and a zone of expansion of a foam. The device enables air to be removed but prevents the foam from escaping outside.

<CIT> discloses door for a refrigerator. The door includes a polygonal shell having corners and defining at least part of a cavity therein and a hinge bearing mounted to the polygonal shell adjacent one of the corners. The hinge bearing extends into the cavity and defines a generally cylindrical passage to receive and journal a hinge pin of the refrigerator appliance. A reinforcement tube is secured to the hinge bearing and extends a distance within the cavity. The reinforcement tube includes a sidewall that defines a hollow interior, and at least one hole extends through the sidewall to provide communication between the cavity and the hollow interior. Insulation is foamed in place that substantially fills the cavity including the corner, and the insulation penetrates into the hollow interior of the reinforcement tube via the at least one hole.

An object of the present invention is to provide a door for a refrigerator, a refrigerator and a method of manufacturing the door, which makes the manufacturing cost lower and the quality of products of the door higher.

To achieve one of the above objects of the present invention, there are provided a door for a refrigerator, a refrigerator, and a method of manufacturing a door for a refrigerator, according to the appended set of claims.

As compared with the prior art, the present invention has the following advantageous effects: with the technical solutions being employed, the material overflow preventing assembly comprises the receiving cavity communicated with the air discharge hole, and the material discharging passage communicated with the receiving cavity, the air discharge hole is communicated with the external, and the material discharging passage is communicated with the receiving space. Therefore, the foaming material is in a gelation state upon passing through the material discharging passage, and gathers in the receiving cavity after passing through the material discharging passage. When the foaming material advances forward into the receiving cavity under a pressure, the foaming material will transition from the gelation state to a cured state and the foaming fluidity is very poor, so the foaming material will not overflow through the air discharge hole out of the door frame, and the air in the receiving space after foaming will be discharged through the air discharge hole. To sum up, no foaming material outside the door frame need be manually cleaned additionally, thereby substantially reducing the manufacturing cost and improving the quality of products.

The present invention will be described in detail below in conjunction with specific embodiments shown in the figures. However, these embodiments are not intended to limit the present invention. Variations in structures, methods or functions made by those having ordinary skill in the art according to these embodiments are all comprised in the extent of protection of the present invention.

In the depictions of the specific embodiments of the present invention, directional or positional relationship as indicted by terms such as "up", "down", "front", "rear", "left", "right", "vertical", "horizontal", "bottom", "in" and "out" is based on the directional or positional relationship shown in the figures usually with reference to the normal in-use state of the refrigerator, and does not indicate that the designated position or element must be in a specific direction.

Moreover, it should be appreciated that although the terms such as "first" and "second" may be used to describe various elements or structures herein, the described objects should not be limited by the above terms. The above terms are only used to distinguish the described objects from each other. For example, a first side plate may also be referred to as a second side plate, and also the second side plate may also be referred to as the first side plate, which does not depart from the extent of protection of the present invention.

As shown in <FIG>, an embodiment of the present invention provides a refrigerator comprising a cabinet (not shown) and a door <NUM> connected to the cabinet, wherein the cabinet defines a storage space, and the door <NUM> is operable to open or close at least part of the storage space. The storage space may comprise a plurality of storage components whose number and structural forms may be configured according to different needs. The storage components usually comprise a refrigerating chamber and a freezing chamber.

Further referring to <FIG>, the door <NUM> comprises a door frame <NUM> enclosed at the periphery, and a first side plate <NUM> and a second side plate <NUM> located on two opposed sides of the door frame <NUM>, the door frame <NUM>, the first side plate <NUM> and the second side plate <NUM> forming a receiving space <NUM> for receiving a foaming material. The door frame <NUM> is provided with at least one material overflow preventing assembly which comprises an air discharge hole <NUM> disposed on the door frame <NUM>, a receiving cavity <NUM> communicated with the air discharge hole <NUM>, and a material discharging passage <NUM> communicated with the receiving cavity <NUM>, the air discharge hole <NUM> is communicated with the external, and the material discharging passage <NUM> is communicated with the receiving space <NUM>.

In the present preferred embodiment, the material overflow preventing assembly comprises the receiving cavity <NUM> communicated with the air discharge hole <NUM>, and the material discharging passage <NUM> communicated with the receiving cavity <NUM>, the air discharge hole <NUM> is communicated with the external, and the material discharging passage <NUM> is communicated with the receiving space <NUM>. Therefore, the foaming material is in a gelation state upon passing through the material discharging passage <NUM>, and gathers in the receiving cavity <NUM> after passing through the material discharging passage <NUM>. When the foaming material advances forward into the receiving cavity <NUM> under a pressure, the foaming material will transition from the gelation state to a cured state and the foaming fluidity is very poor, so the foaming material will not overflow through the air discharge hole <NUM> out of the door frame <NUM>, and the air in the receiving space <NUM> after foaming will be discharged through the air discharge hole <NUM>. As such, no foaming material outside the door frame <NUM> need be manually cleaned additionally, thereby substantially reducing the manufacturing cost and improving the quality of products.

Specifically, the air discharge hole <NUM> extends along an extension axis <NUM>, a plane perpendicular to the extension axis <NUM> is defined as a first plane, a projection area of the receiving cavity <NUM> on the first plane is greater than a projection area of the air discharge hole <NUM> on the first plane, and the projection area of the receiving cavity <NUM> on the first plane is greater than the projection area of the material discharging passage <NUM> on the first plane. It is further ensured that the foaming material reaches a cured state after passing through the narrow material discharging passage <NUM>, and then entering the wide receiving cavity <NUM> under a certain pressure, thereby gathering in the receiving cavity <NUM> and preventing the overflow of the foaming material.

Further referring to <FIG>, each material overflow preventing assembly comprises a plurality of air discharge holes <NUM>, and projections of the plurality of air discharge holes <NUM> on the first plane are all located in a range of the projection of the receiving cavity <NUM> on the first plane. In the present preferred embodiment, four air discharge holes <NUM> are provided, the four air discharge holes <NUM> are uniformly distributed in the receiving cavity <NUM>, and the four air discharge holes <NUM> are all set the same so that they can be processed and manufactured conveniently. Certainly, the air discharge holes <NUM> may be set in another number, and the air discharge holes <NUM> may also set partially the same and partially different. It is also possible to set all the air discharge holes <NUM> different from one another.

Furthermore, the projection of the material discharging passage <NUM> on the first plane is located out of the range of the projection of the receiving cavity <NUM> on the first plane. One, two or more material overflow preventing assemblies may also be provided.

Specifically, the material overflow preventing assembly comprises a protrusion <NUM> formed on the door frame <NUM> and forming the receiving cavity <NUM>, and a cap <NUM> disposed at the outer circumference of the protrusion <NUM> and covering the receiving cavity <NUM>; the protrusion <NUM> extends from the door frame <NUM> inward the receiving cavity <NUM>, and the material discharging passage <NUM> is defined between the protrusion <NUM> and the cap <NUM>.

In the present embodiment, the material discharging passage <NUM> comprises a longitudinal through slot <NUM> disposed on the outer circumference of the protrusion <NUM> and extending in an extension direction of the protrusion <NUM>, the longitudinal through slot <NUM> is communicated with the receiving space <NUM>, and remaining outer circumference of the protrusion <NUM> except for the longitudinal through slot <NUM> abuts against an inner side of the cap <NUM>. Such an arrangement makes the structure simple and easy to manufacture. A plurality of longitudinal through slots <NUM> are provided and evenly distributed on the outer circumference of the protrusion <NUM>. Certainly, the plurality of longitudinal through slots <NUM> may not be evenly distributed on the outer circumference of the protrusion <NUM>. In the present embodiment, four longitudinal through slots <NUM> are provided, and may also be set in another number. The protrusion <NUM> is set in a cylindrical shape, and certainly may also be set in another shape. The four longitudinal through slots <NUM> are evenly distributed on the outer circumference of the protrusion <NUM>. Certainly, the four longitudinal through slots <NUM> may also be set to be arranged unevenly. In addition, the four longitudinal through slots <NUM> are set to be the same so that they can be processed and manufactured conveniently. Likewise, the four longitudinal through slots <NUM> may also be set partially the same and partially different. Certainly, the four longitudinal through slots <NUM> may also be set different from one another.

In addition, the material discharging passage <NUM> may also be set in other structural forms in addition to the longitudinal through slot <NUM>, so long as a passage is formed between the protrusion <NUM> and the cap <NUM> to communicate the receiving space <NUM> with the receiving cavity <NUM>. For example, the longitudinal through slot <NUM> is not disposed on the outer circumference of the protrusion <NUM>, and a certain gap is ensured between the outer circumference of the protrusion <NUM> and the cap <NUM> to form the material discharging passage <NUM> to allow the foaming material and air to pass therethrough.

Referring to <FIG>, the door frame <NUM> comprises an upper molding strip <NUM>, a lower molding strip <NUM> opposed to the upper molding strip <NUM>, a left side rim <NUM> and a right side rim <NUM> opposed to the left side rim <NUM>, the left side rim <NUM> and right side rim <NUM> are connected to the upper molding strip <NUM> and lower molding strip <NUM>, and the material overflow preventing assembly is disposed on the upper molding strip <NUM> and/or lower molding strip <NUM>. In the present embodiment, both the upper molding strip <NUM> and lower molding strip <NUM> are provided with the material overflow preventing assembly. The material overflow preventing assemblies on the upper molding strip <NUM> and lower molding strip <NUM> may be set to be symmetrical with each other. Certainly, the material overflow preventing assemblies on the upper molding strip <NUM> and lower molding strip <NUM> may also be set asymmetrical. In addition, the structural forms of the material overflow preventing assemblies on the upper molding strip <NUM> and lower molding strip <NUM> may be set completely the same. Likewise, the structural forms of the material overflow preventing assemblies on the upper molding strip <NUM> and lower molding strip <NUM> may also be set not completely the same.

The air discharge hole <NUM> comprises a conical hole portion communicated with the receiving cavity <NUM> and a round hole portion connected with the conical hole portion, the round hole portion being connected with the external. Such an arrangement enables a better air-discharging performance and better prevents the overflow of the material.

Furthermore, the cap <NUM> comprises an edge portion <NUM> abutting against the door frame <NUM> and a bottom portion <NUM> opposed to the edge portion <NUM>, the bottom portion <NUM> is used to enclose the receiving cavity <NUM>, the material discharging passage <NUM> further comprises a groove <NUM> disposed on the door frame <NUM> and communicated with the longitudinal through slot <NUM>, and an extension direction of the groove <NUM> is perpendicular to the extension direction of the longitudinal through slot <NUM>. Each longitudinal through slot <NUM> is communicated with the groove <NUM> so that the foaming material and air enter the longitudinal through slot <NUM> through the groove <NUM> and then enter the receiving cavity <NUM>.

The present invention further provides a method of manufacturing a door <NUM> for a refrigerator, wherein the method comprises:.

In the present preferred embodiment, the first side plate <NUM> is a front panel forming the front of the door <NUM>, and the second side plate <NUM> is a door liner forming the rear of the door <NUM>. Certainly, the first side plate <NUM> may also set as the door liner forming the rear of the door <NUM>, and correspondingly, the second side plate <NUM> is set as the front panel forming the front of the door <NUM>. In the manufacturing process, a mold is used to attach the first side plate <NUM> to the door frame <NUM>, then the foaming material is injected, then the mold is used to mount the second side plate <NUM>, and finally the foaming material foams and expands. Partial foaming material enters the receiving space <NUM> as air is pushed and pressed, and gets cured in the receiving space <NUM>, and air is discharged out through the air discharge port <NUM>, thereby preventing the overflow of the foaming material so that no foaming material need be manually cleaned, reducing the processing and manufacturing cost, making the door <NUM> pleasant in appearance and improving the quality of products.

It should be understood that although the description is described according to the embodiments, not every embodiment only comprises one independent technical solution, that such a description manner is only for the sake of clarity, that those skilled in the art should take the description as an integral part, and that the technical solutions in the embodiments may be suitably combined to form other embodiments understandable by those skilled in the art.

Claim 1:
A door (<NUM>) for a refrigerator, the door (<NUM>) comprising a door frame (<NUM>) enclosed at a periphery, and a first side plate (<NUM>) and a second side plate (<NUM>) located on two opposed sides of the door frame (<NUM>) , the door frame (<NUM>) , the first side plate (<NUM>) and the second side plate (<NUM>) forming a receiving space (<NUM>) for receiving a foaming material, wherein
the door frame (<NUM>) is provided with at least one material overflow preventing assembly which comprises an air discharge hole (<NUM>) disposed on the door frame (<NUM>), characterized in that the at least one material overflow preventing assembly further comprises a receiving cavity (<NUM>) communicated with the air discharge hole (<NUM>) , a hollow protrusion(<NUM>) formed on the door frame (<NUM>) and forming the receiving cavity (<NUM>) , a cap (<NUM>) disposed at an outer circumference of the protrusion (<NUM>) and covering the receiving cavity (<NUM>) , and a material discharging passage (<NUM>) communicated with the receiving cavity (<NUM>) , the air discharge hole (<NUM>) is communicated with the external, a cap (<NUM>) disposed at an outer circumference of the protrusion (<NUM>) and covering the receiving cavity (<NUM>) , and the material discharging passage (<NUM>) is communicated with the receiving space and is defined between the protrusion (<NUM>) and the cap (<NUM>) ;
the air discharge hole (<NUM>) extends along an extension axis (<NUM>) , a plane perpendicular to the extension axis (<NUM>) is defined as a first plane, a projection area of the receiving cavity (<NUM>) on the first plane is greater than a projection area of the air discharge hole (<NUM>) on the first plane, and the projection area of the receiving cavity (<NUM>) on the first plane is greater than the projection area of the material discharging passage (<NUM>) on the first plane.