Door for refrigerator

Abstract

An outer door of a door for a refrigerator according to the present invention has a front portion defining a front surface, and first and second side portions defining side surfaces of the door by being bent rearward from both lateral sides of the front portion. A door bracket made of synthetic resin is connected to a rear end of the second side portion to define a part of one of the side surfaces. A door liner defining a rear surface of the door is fixed to a rear end of the first side portion and to a rear end of the door bracket. An inner frame for supporting the both side surfaces of the door upon contraction of a foaming liquid injected into the interior of the door comprises a first supporting portion that is in close contact with an inner surface of the first side portion, a second supporting portion that is in close contact with an inner side of the door bracket, and a supporting bar for connecting and supporting the first and second supporting portions.

Description

BACKGROUND OF THE INVENTION

1. Field of the Invention

The present invention relates to a refrigerator, and more particularly, to an inner frame for a refrigerator, which prevents damage to an external appearance of a door due to contraction generated upon cooling of a foaming liquid that has been foamed in the interior of the door for the refrigerator.

2. Description of the Prior Art

FIG. 1 exemplarily shows a sectional view of a conventional door for a refrigerator.

As shown in the figure, the door 1 comprises a metallic outer door 3 defining a front surface, and a door liner 5 defining a rear surface of the door 1. Decoration caps 7 are attached to upper and lower end surfaces of the door 1, respectively, and decoration covers 9 are attached to both side surfaces of the door 1, respectively.

The interior of the door 1 defined by the outer door 3, the door liner 5, the decoration caps 7 and the decoration covers 9 is filled with a foaming liquid. The foaming liquid filled into the door is solidified to form an insulation layer 10 that insulates an inner storage space of the refrigerator from the outside of the refrigerator.

However, the conventional door for a refrigerator constructed as above has the following problems.

As described above, the foaming liquid that has been foamed in the interior of the door 1 is solidified to from the insulation layer 10. However, while the foaming liquid that has been foamed in the interior of the door 1 is solidified, the volume of the foaming liquid decreases. As the volume of the foaming liquid decreases, there may be a risk that an external appearance of the door 1 will be distorted.

Such distortion of appearance of the door 1 may cause a poor external appearance of the door as well as various other problems. For example, the deformation of the decoration covers defining the side surfaces of the door may cause distortion of the shape of a gasket for preventing leakage of cold air, so that the deformed gasket cannot completely seal the inner storage space of the refrigerator. In case of a side-by-side type refrigerator in which a gasket (not shown) provided at a side surface of the door 1 is in close contact with a gasket provided at a side surface of another door (not shown), the deformation of the decoration cover 9 of the door 1 causes the gaskets not to be in completely close contact with each other. Therefore, there is a disadvantage in that cold air in the storage space hermetically closed by the door 1 leaks out.

SUMMARY OF THE INVENTION

The present invention is conceived to solve the aforementioned problems in the prior art. An object of the present invention is to provide a door for a refrigerator, which can prevent an external appearance of the door from being distorted.

According to the present invention for achieving the objects, there is provided a door for a refrigerator, comprising an outer door having a front portion defining a front surface, and first and second side portions that define side surfaces and are formed by being bent rearward from both lateral sides of the front portion; a door liner connected to rear ends of the side portions to define a rear surface of the door; and an inner frame having first and second supporting portions that are in close contact with inner surfaces of the first and second side portions, respectively, and a supporting bar for connecting and supporting the first and second supporting portions.

In order to ensure a smooth flow of a foaming liquid injected into the interior of the door to form an insulation layer, the supporting portions and the supporting bar may be formed with a plurality of openings.

The supporting portions and the supporting bar may be perpendicular to each other. This is more advantageous to prevention of deformation caused upon contraction of the foaming liquid.

In another embodiment, the door may comprise a plurality of supporting bars, and at least one reinforcement member for connecting the supporting bars to one another in a vertical direction.

A door for a refrigerator according to a further embodiment of the present invention comprises an outer door having a front portion defining a front surface, and first and second side portions that define side surfaces and are formed by being bent rearward from both lateral sides of the front portion; a door bracket that is made of synthetic resin and connected to a rear end of the second side portion to form a part of one of the side surfaces; a door liner fixed to a rear end of the first side portion and to a rear end of the door bracket to form a rear surface of the door; and an inner frame having a first supporting portion that is in close contact with an inner surface of the first side portion, a second supporting portion that is in close contact with an inner side of the door bracket, and a supporting bar for connecting and supporting the first and second supporting portions.

In a still further embodiment, the door bracket may be connected to the second side portion by inserting a flange extending inward at the rear end of the second side portion into an insertion groove that is open outward at a front portion of the door bracket.

The door bracket may be provided, at an outer surface thereof, with an installation space for receiving a door gasket to be installed therein.

The first supporting portion may comprise a contacting section that is in close contact with the entire first side portion, and a supporting section formed inward from the contacting section, and the first supporting portion may be connected to the supporting bar at the supporting section.

The second supporting portion may be in surface contact with and support the door bracket.

The second supporting portion may be in close contact with and supported by a seating step with a tip extending inwardly from the door bracket. Upper and lower ends of the second supporting portion may be supported by a pair of supporting protrusions formed on the door bracket, so that the second supporting portion can be firmly supported without a vertical play.

The first supporting portion may be made of synthetic resin, and the second supporting portion and the supporting bar may be made of metal. Outer surfaces of the door bracket and the second side portion of the outer door may be flush with each other.

According to the present invention constructed as above, even though the foaming liquid is contracted during solidification of the foaming liquid that has been foamed in the interior of the door for the refrigerator, the inner frame securely supports both inner surfaces of the door, thereby preventing distortion of an external appearance of the door.

BRIEF DESCRIPTION OF THE DRAWINGS

The above and other objects, features and advantages of the present invention will become apparent from the following description of preferred embodiments given in conjunction with the accompanying drawings, in which:

FIG. 1 is a partial side sectional view showing a conventional door for a refrigerator;

FIG. 2 is a cross sectional view showing an example of a door with an inner frame according to the present invention;

FIG. 3 is a perspective view showing a part of a door bracket in the present invention;

FIG. 4 is a perspective view showing the inner frame in the present invention;

FIG. 5 is an exemplary front view showing a relationship between the inner frame and a first supporting portion; and

FIG. 6 is an exemplary rear view showing a relationship between the inner frame and the first supporting portion.

DESCRIPTION OF THE PREFERRED EMBODIMENTS

Hereinafter, a preferred embodiment of a door for a refrigerator according to the present invention will be described in detail with reference to the accompanying drawings.

FIG. 2 shows a cross section of a door for a refrigerator according to an embodiment of the present invention, FIG. 3 shows a door bracket in the present invention, and FIG. 4 shows a perspective view of an inner frame in the present invention.

A shown in the figures, the door 30 of this embodiment comprises an outer door 31 defining a front surface and both side surfaces; a door liner 35 defining a rear surface of the door; a door bracket 37 defining a part of one of the side surfaces of the door; and an inner frame 40 provided in the interior of the door to secure rigidity.

The outer door 31 defining the front surface of the door is made of metal and comprises a front portion 32 defining a front appearance of the door 30 and side portions 33 and 34 bent at both lateral ends of the front portion 32 at a right angle to define appearances of the both side surfaces of the door 30.

The front portion 32 can be modified in view of its design. For example, a central portion can be rounded convexly. Further, the first side portion 33 of the side portions 33 and 34 defines an entire appearance of one of the side surfaces of the door 30, and the second side portion 34 of the side portions 33 and 34 defines a front part of the other side surface of the door 30.

Flanges 33a and 34a are formed at rear ends of the side portions 33 and 34, respectively. The flanges 33a and 34a are used for installing the door liner 35 and the door bracket 37 to be described below. The flanges are bent inward at the rear ends of the first and second side portions 33 and 34, respectively, to face each other and then extend by predetermined lengths.

Moreover, the door liner 35 is made of synthetic resin and defines the rear surface of the door. The door liner 35 may be provided, at a rear surface thereof, with a certain receiving space for mounting a door basket (not shown) used for receiving articles therein. The flange 33a of the first side portion 33 is fixed to one side surface of the door liner 35, and a rear end of the door bracket 37 to be described below is fixed to the other side surface of the door liner.

Further, decoration caps (not shown) are mounted at upper and lower surfaces of the door 30 even in the present invention. The outer door 31, the door liner 35 and the door bracket 37 are fixed to peripheries of the decoration caps.

The door bracket 37 is installed at the rear of the second side portion 34 of the door 30 and is made of synthetic resin. The door bracket 37 is longitudinally elongated to correspond to the length of the door 30 while having a predetermined width.

Moreover, an insertion groove 37a is formed longitudinally at a front end of the door bracket 37. The insertion groove 37a is open outward from the door bracket 37 and is formed to be elongated longitudinally throughout the door bracket 37 so that the flange 34a of the second side portion 34 can be fixedly inserted thereinto.

In a state where the flange 34a of the second side portion 34 has been inserted into the insertion groove 37a, it is preferred that outer side surfaces of the door bracket 37 and the second side portion 34 be flush with each other. To this end, portions of the door bracket 37 on both sides with respect to the insertion groove 37a are stepped in height as much as the thickness of the second side portion 34.

Furthermore, a flange 37b is provided at a rear end of the door bracket 37, which corresponds to a side opposite to the insertion groove 37. The flange 37b is used for fixing the door liner 35 and the door bracket 37 and is in close contact with an inner surface of an end of the door liner 35. The flange 37b is also formed to be longitudinally elongated throughout the door bracket 37.

Additionally, the door bracket 37 is provided with a seating step 37c, and a pair of supporting protrusions 37d spaced apart vertically from each other at an interval. As shown in FIGS. 2 and 3, the seating step 37c protrudes substantially perpendicularly from an inner surface of the door bracket 37 toward the first side portion 33 and has a predetermined height. A front end of a second supporting portion 45 of the inner frame 40 to be described below is seated on the seating step 37c. The seating step 37c has a sufficient dimension enabling the seating step 37c to come into contact with and support at least a part of the second supporting portion 45.

The pair of supporting protrusions 37d are provided on the inner surface of the door bracket 37 to be spaced apart from each other at a distance corresponding to the vertical length of the second supporting portion 45. Accordingly, in a state where the second supporting portion 45 is seated on the seating step 37c, upper and lower ends of the second supporting portion 45 are supported by the upper and lower supporting protrusions 37d, respectively.

An installing space 38 is formed at one side of the door bracket 37 throughout the entire length of the door bracket. The installing space 38 is a space in which a gasket (not shown) provided at the door 30 will be installed.

Meanwhile, the inner frame 40 is installed in the interior of the door 30 to reinforce rigidity against an external force generated when a foaming liquid is contracted. The inner frame 40 is to support the both side surfaces of the door 30, and comprises first and second supporting portions 41 and 45, which are in close contact with inner sides of the both side surfaces of the door 30, respectively, and supporting bars 46 for connecting the first and second supporting portions 41 and 45 to each other, as shown in FIG. 4.

The first supporting portion 41 is made of synthetic resin such as plastic, and comprises a contacting section 42 with one side in close contact with an inner surface of the first side portion 33 and a fixing section 43 provided at an inner surface of the contacting section 42. The contacting section 42 and the fixing section 43 are formed with a plurality of openings 42a and 43a through which the foaming liquid to be foamed in the interior of the door 30 can flow, respectively.

It is preferred that the contacting section 42 be formed to be elongated longitudinally and front and rear ends of the contacting section be in close contact with an edge between the front portion 32 and the first side portion 33 and with an edge between the first side portion 33 and the flange 33a. That is, it is preferred that the contacting section 42 of the first supporting portion 41 be in surface contact with the entire first side portion to prevent the occurrence of a play in a fore and aft direction. Further, it is preferred that the fixing section 43 extend inwardly at a substantially central position on an inner surface of the contacting section 42. More preferably, the fixing section 43 is perpendicular to the contacting section in view of rigidity.

The second supporting portion 45 is in close contact with the inner surface of the door bracket 37. It is preferred that the second supporting portion 45 be made of metal and also formed with a plurality of openings 45a through which the foaming liquid flows. It is preferred that the length of the second supporting portion 45 correspond to that of the first supporting portion 41, and the width of the second supporting portion 45 in the fore and aft direction correspond to a distance from the seating step 37c to the rear end of the door bracket 37. It is desirable that the second supporting portion 45 be in surface contact with the inner surface of the door bracket 37 to stably support the door bracket 37. Therefore, it is desirable that the second supporting portion 45 extend rearward to have a certain area as in the illustrated embodiment.

Meanwhile, an end of the second supporting portion 45, which is in the vicinity of the rear surface of the front portion 32, is seated on the seating step 37c. In the state where the end of the second supporting portion 45 is seated on the seating step 37c as described above, the upper and lower ends of the second supporting portion 45 are supported by the supporting protrusions 37d.

Both ends of each of the supporting bars 46 are fixed to the first and second supporting portions 41 and 45, respectively, so that the supporting bar 46 substantially supports the both side surfaces of the door 30. It is desirable that the supporting bar 46 be perpendicular to the first and second supporting portions 41 and 45. The supporting bar 46 is made of metal, and the supporting bar 46 is also formed with a plurality of openings 46a through which the foaming liquid flows.

As for embodiments of fixing the end of the supporting bar 46 to the first supporting portion 41, as shown in FIGS. 5 and 6, the fixing section 43 is formed with a plurality of fastening holes 44a and is provided with fastening slots 44b in the vicinity of the fastening holes 44a. Further, catching steps 44c are provided at a front end of the fixing section 43 in the vicinity of the fastening slots 44b.

Meanwhile, at least one fastening bracket 47 and fastening hook 48 are provided at the corresponding end of the supporting bar 46. Each of the fastening bracket 47 and the fastening hook 48 extends by a predetermined length outward from the end of the supporting bar 46 and is formed by longitudinally cutting out the end of the supporting bar 46.

A front surface of the fastening bracket 47 is in close contact with a rear surface of the fixing section 43, and the fastening bracket 47 is formed with fastening holes 47a corresponding to the fastening holes 44a of the fixing section 43. In the state where the fastening bracket 47 is in close contact with the fixing section 43, a screw S penetrates through the fastening hole 47a of the fastening bracket 47 and is fastened to the fastening hole 44a of the fixing section 43. The fastening hook 48 is inserted into the fastening slot 44b from the rear of the fixing section 43 and a catching protrusion 48a of the fastening hook 48 penetrates through the fastening slot 44b and is then caught by the catching steps 44c.

As described above, the supporting bar 46 can be securely fixed to the first supporting portion 41 in such a manner that the fastening bracket 47 is fastened to the fixing section 43 by the screw and the fastening hook 48 is caught by an end of the catching step 44c after penetrating through the fastening slot 44b.

It is preferred that the other end of the supporting bar 46 be fixed to the second supporting portion 45 by means of welding. However, the method of fixing the supporting bar 46 to the second supporting portion 45 is not limited thereto. It is possible to use other mechanical elements so far as both the second supporting portion 45 and the supporting bar 46 can be securely fixed to each other.

Further, the structural rigidity of the inner frame 40 can be enhanced more greatly by installing a reinforcement member 49 for connecting the plurality of supporting bars 46. The reinforcement member 49 is made of metal and connects the plurality of supporting members 46 in a vertical direction by means of welding or the like. In the illustrated embodiment, the reinforcement member 49 is welded vertically to the supporting bars 46 at positions in the vicinity of the first supporting portion 41. Moreover, the reinforcement member 49 is also formed with a plurality of openings 49a so that the foaming liquid can flow therethrough.

Next, a process for assembling the door for a refrigerator according to the present invention will be described.

First, an end of each of the supporting bars 46 is fixedly welded to one side of the second supporting portion 45. Then, the reinforcement member 49, which vertically connects the plurality of supporting bars 46 fixed to the second supporting portion 45, is fixedly welded to the supporting bars 46 at proper positions. In the illustrated embodiment, the reinforcement member 49 is fixed to the supporting bars 46 by means of welding at positions on a side opposite to the second supporting portion. Accordingly, the supporting bars 46 are connected to one another by the second supporting portion 45 and the reinforcement member 49.

In such a state mentioned above, the front surface of the fastening bracket 47 of each of the supporting bars 46 comes into close contact with the rear surface of the fixing section 43 of the first supporting portion 41. At this time, the fastening hole 44a of the fixing section 43 and the fastening hole 47a of the fastening bracket 47 are located to correspond to each other. The fastening hook 48 of the supporting bar 46 penetrates through the fastening slot 44b of the fixing section 43.

The catching protrusion 48a of the fastening hook 48, which has penetrated through the fastening slot 44b, is caught by the catching step 44c of the fixing section 43. Then, the screw S is caused to penetrate through the fastening holes 47a of the fastening bracket 47 and to be fastened to the fastening hole 44a of the fixing section 43 so that the first supporting portion 41 and the supporting bar 46 are fixed to each other. When the inner frame is completely assembled through the above processes, the door is assembled as a whole.

First, to assemble the door 30, the front portion 32 of the outer door 31 is placed on a floor, and the flange 34a of the second side portion 34 of the outer door 31 is inserted in the insertion groove 37a of the door bracket 37 so that the door bracket 37 is fixed to the second side portion 34. Then, the decoration caps are fixed to the upper and lower ends of the outer door 31 and the door bracket 37.

In this state, the inner frame 40 is installed in the interior of the door 30, i.e., the space defined by the outer door 31, the decoration caps and the door bracket 37. To this end, the first supporting portion 41 of the inner frame 40 comes into close contact with the inner surface of the first side portion 33 of the outer door 31.

Further, the second supporting portion 45 of the inner frame 40 comes into close contact with the inner surface of the door bracket 37. At this time, the front surface of the second supporting portion 45 is seated on the seating step 37c of the door bracket 37, and the upper and lower ends of the second supporting portion 45 are supported by the pair of the supporting protrusions 37d of the door bracket 37, so that the inner frame 40 is firmly supported.

When the inner frame 40 is completely installed as described above, the flange 33a of the first side portion 33 and the flange 37b of the door liner 35 come into close contact with and are fixed to the inner surface of the door liner 35. Then, the foaming liquid is injected into the interior of the door 30 via an injection port (not shown).

The foaming liquid injected into the interior the door 30 is solidified after lapse of a predetermined period of time to form an insulation layer. Accordingly, with the solidification of the foaming liquid, the inner frame 40 is completely fixed in place within the interior of the door 30. Thus, the process of assembling the door 30 is completed.

However, since the foaming liquid is contracted during the solidification, external forces that act toward the interior of the door are exerted on the respective surfaces defining the door 30. According to the present invention, since the both side surfaces of the door are securely supported by the inner frame 40, deformation of the both side surfaces of the door 30 can be prevented.

The deformation of the door 30 caused by changes in the volume of the foaming liquid is significantly generated at the door bracket 37 made of synthetic resin. According to the present invention, since the door bracket 37 is supported in the state where it is in close contact with the second supporting portion 45 of the inner frame 40, the door can be supported without deformation due to the external forces generated by the contraction of the foaming liquid.

Further, since the inner surface of the first side portion 33 of the door 30 is firmly supported by the first supporting portion 41 made of synthetic resin, the first side portion 33 of the door can also sufficiently resist against the deformation caused by the contraction of the foaming liquid.

According to the present invention described above, it can be understood that the basic technical spirit of the present invention is to install the inner frame, which supports the both side surfaces of the door for the refrigerator, within the interior of the door.

With the inner frame of the door for a refrigerator according to the present invention, it is expected to obtain the following advantageous effects.

First, during solidification of a foaming liquid that has been foamed in the interior of the door for the refrigerator, it is possible to prevent damage to an external appearance of the door caused by decrease in the volume of the foaming liquid.

Since the deformation of side surfaces of the door is prevented, a side surface of the door is in close contact with a side surface of another door, thereby preventing leakage of cold air within a storage space of the refrigerator.

It will be apparent to those skilled in the art that various changes and modifications can be made thereto without departing from the scope and spirit of the present invention. Therefore, the scope of the present invention should be construed as being defined by the appended claims.

Claims

1. A door for a refrigerator, comprising:

an outer door having a front portion defining a front surface, and first and second side portions defining side surfaces, the first and second side portions being formed by being bent rearward from both lateral sides of the front portion;

a door liner connected to rear ends of the side portions to define a rear surface of the door; and

an inner frame having first and second supporting portions that are in close contact with inner surfaces of the first and second side portions, respectively, and a supporting bar for connecting and supporting the first and second supporting portions.

2. The door as claimed in claim 1, wherein the supporting portions and the supporting bar are formed with a plurality of openings.

3. The door as claimed in claim 1, wherein the supporting portions and the supporting bar are perpendicular to each other.

4. The door as claimed in claim 1, comprising a plurality of supporting bars, and at least one reinforcement member for connecting the supporting bars to one another in a vertical direction.

5. A door for a refrigerator, comprising:

an outer door having a front portion defining a front surface, and first and second side portions defining side surfaces, the first and second side portions being formed by being bent rearward from both lateral sides of the front portion;

a door bracket made of synthetic resin, the door bracket being connected to a rear end of the second side portion to form a part of one of the side surfaces;

a door liner fixed to a rear end of the first side portion and to a rear end of the door bracket to form a rear surface of the door; and

an inner frame having a first supporting portion that is in close contact with an inner surface of the first side portion, a second supporting portion that is in close contact with an inner side of the door bracket, and a supporting bar for connecting and supporting the first and second supporting portions.

6. The door as claimed in claim 5, wherein the supporting portions and the supporting bar are formed with a plurality of openings.

7. The door as claimed in claim 5, wherein the supporting portions and the supporting bar are perpendicular to each other.

8. The door as claimed in claim 5, comprising a plurality of supporting bars, and at least one reinforcement member for connecting the supporting bars to one another in a vertical direction.

9. The door as claimed in claim 5, wherein the door bracket is connected to the second side portion by inserting a flange extending inward at the rear end of the second side portion into an insertion groove that is open outward at a front portion of the door bracket.

10. The door as claimed in claim 5, wherein the door bracket is provided with an installation space at an outer surface thereof, the installing space receiving a door gasket to be installed therein.

11. The door as claimed in claim 5, wherein the first supporting portion comprises a contacting section that is in close contact with the entire first side portion, and a supporting section formed inward from the contacting section, and the first supporting portion is connected to the supporting bar at the supporting section.

12. The door as claimed in claim 11, wherein the second supporting portion is in surface contact with and supports the door bracket.

13. The door as claimed in claim 11 or 12, wherein the second supporting portion is in close contact with and supported by a seating step with a tip extending inwardly from the door bracket.

14. The door as claimed in claim 11 or 12, wherein upper and lower ends of the second supporting portion are supported by a pair of supporting protrusions formed on the door bracket.

15. The door as claimed in claim 5, wherein the first supporting portion is made of synthetic resin, and the second supporting portion and the supporting bar are made of metal.

16. The door as claimed in claim 5, wherein outer surfaces of the door bracket and the second side portion of the outer door are flush with each other.