Seamless refrigerator liner and process for manufacturing same

Abstract

A process for manufacturing a seamless refrigerator liner involves providing a plastic refrigerator box liner having an opening providing access to the interior thereof and a flange around each opening. A casing is positioned over the liner, the casing having an opening corresponding to the opening in the liner such that the flange of the liner opening extends through the casing opening. The flange is heated such that it melts and conforms to the shape of the casing opening thereby forming a seamless joint.

1 . A process for manufacturing a seamless refrigerator liner, comprising the steps of:
 providing a plastic refrigerator box liner having an opening which provides access to the interior thereof, the liner opening having a flange;   insulating the liner around the liner opening;   positioning a casing over the liner, the casing having an opening corresponding to the liner opening such that the flange of the liner opening extends through the casing opening; and   heating the flange extending through the casing opening such that it melts and conforms to the shape of the casing opening to form a seamless breaker joint.   
   
   
       2 . The process of  claim 1 , including the step of cutting an offset frame of the liner to form the liner opening, the offset frame having a flange. 
   
   
       3 . The process of  claim 1 , wherein the casing comprises an outer shell, a front face, and a top cover. 
   
   
       4 . The process of  claim 3 , including the step of cutting the front face of the casing to form the casing opening. 
   
   
       5 . The process of  claim 1 , wherein the heating step includes the step of using a jet air furnace. 
   
   
       6 . The process of  claim 1 , further comprising the steps of inserting the refrigerator box liner into an insulation mold and injecting polyurethane foam insulation into a gap between the liner and the mold. 
   
   
       7 . The process of  claim 1 , wherein the liner includes an offset frame with a flange on a top counter. 
   
   
       8 . The process of  claim 7 , including the steps of cutting a second liner opening in the offset frame on the top counter, cutting a top cover of the casing to form a second casing opening, aligning the second casing opening with the second liner opening such that the flange of the second liner opening extends through the second casing opening, and heating the flange extending through the second casing opening such that it melts and conforms to the shape of the second casing opening to form a seamless breaker joint. 
   
   
       9 . The process of  claim 1 , further comprising the step of installing a refrigerator door over the opening. 
   
   
       10 . A process for manufacturing a seamless refrigerator liner, comprising the steps of:
 providing a plastic refrigerator box liner having a first offset frame with a flange on a front face and a second offset frame with a flange on a top counter;   cutting the first offset frame to form a first liner opening which provides access to the interior of the liner, the first liner opening having a flange;   cutting the second offset frame to form a second liner opening, which provides access to the interior of the liner, the second liner opening having a flange;   insulating the liner around the first and second liner openings;   positioning a casing over the liner, the casing having openings corresponding to the first and second liner openings such that the flanges of the first and second liner openings extend through the casing openings; and   heating the flanges extending through the casing openings such that they melt and conform to the shape of the corresponding casing openings to form seamless breaker joints.   
   
   
       11 . The process of  claim 10 , wherein the casing comprises an outer shell, a front face, and a top cover, and including the step of cutting the front face and the top cover of the casing to form the casing openings. 
   
   
       12 . The process of  claim 10 , wherein the heating step includes the step of using a jet air furnace. 
   
   
       13 . The process of  claim 10 , further comprising the steps of inserting the refrigerator box liner into an insulation mold, injecting polyurethane foam insulation into a gap between the liner and the mold, and installing refrigerator doors over the openings. 
   
   
       14 . A seamless refrigerator liner, comprising:
 a plastic refrigerator box liner having an opening providing access to the interior thereof and a flange around the liner opening;   a casing surrounding the liner, the casing having an opening corresponding to the liner opening such that the flange extends through the casing opening; and   a seamless breaker joint around the casing opening formed by melting the flange.   
   
   
       15 . The seamless refrigerator liner of  claim 14 , wherein the liner is made from linear low-density polyethylene. 
   
   
       16 . The seamless refrigerator liner of  claim 14 , wherein the liner has three front openings. 
   
   
       17 . The seamless refrigerator liner of  claim 15 , wherein the liner has one top opening. 
   
   
       18 . The seamless refrigerator liner of  claim 14 , further comprising insulation between the liner and the casing. 
   
   
       19 . The seamless refrigerator liner of  claim 18 , wherein the insulation comprises polyurethane foam. 
   
   
       20 . The seamless refrigerator liner of  claim 14 , wherein the casing comprises stainless steel.