Refrigerator appliance and a method for manufacturing the same

Abstract

The present subject matter provides a refrigerator appliance and a method for manufacturing the same. The method includes applying a polyurethane elastomer onto a surface of an inner liner of the refrigerator appliance and injecting a polyurethane foam into a cavity defined between an outer case of the refrigerator appliance and the inner liner. The polyurethane elastomer can limit or prevent leakage of the polyurethane foam from the cavity.

What is claimed is: 
     
         1 . A method for assembling a refrigerator appliance, comprising:
 providing an outer case of the refrigerator appliance and an inner liner of the refrigerator appliance;   mounting the inner liner to the outer case such that the inner liner and the outer case define a cavity therebetween;   applying a polyurethane elastomer onto a surface of the inner liner; and   injecting a polyurethane foam into the cavity between the outer case and the inner liner.   
     
     
         2 . The method of  claim 1 , further comprising heating the outer case, the inner liner and the polyurethane elastomer prior to said step of injecting. 
     
     
         3 . The method of  claim 1 , wherein the inner liner comprises a first portion and a second portion, the first and second portions of the inner liner mounted to each other such that the first and second portions of the inner liner define a seam therebetween, wherein said step of applying comprises applying the polyurethane elastomer onto the inner liner at the seam of the inner liner. 
     
     
         4 . The method of  claim 1 , wherein the inner liner defines an opening, wherein said step of applying comprises applying the polyurethane elastomer onto the inner liner at the opening of the inner liner. 
     
     
         5 . The method of  claim 1 , further comprising attaching a rear panel to the outer case after said step of applying and prior to said step of injecting. 
     
     
         6 . The method of  claim 1 , wherein the polyurethane elastomer has a temperature between about sixty-five degrees Fahrenheit and about one-hundred degrees Fahrenheit during said step of applying. 
     
     
         7 . The method of  claim 1 , wherein the inner liner defines an interior volume of the refrigerator appliance, wherein said step of applying comprises applying the polyurethane elastomer onto the surface of the inner liner such that the polyurethane elastomer on the surface of the inner liner hinders the polyurethane foam from entering the interior volume of the inner liner during said step of injecting. 
     
     
         8 . The method of  claim 1 , wherein said step of applying comprises applying the polyurethane elastomer onto the surface of the inner liner with a wand having a spray head, the wand having a length about equal to a depth of the cavity between the inner liner and the outer case. 
     
     
         9 . The method of  claim 1 , wherein the polyurethane elastomer has a temperature less than a melting temperature of the inner liner during said step of applying. 
     
     
         10 . The method of  claim 1 , further comprising curing the polyurethane foam within the cavity between the outer case and the inner liner such that the polyurethane foam extends between the inner liner and the outer case within the cavity after said step of curing. 
     
     
         11 . A refrigerator appliance, comprising:
 an outer case;   an inner liner spaced apart from the outer case such that the inner liner and the outer case define a cavity therebetween, the inner liner defining an interior volume configured for receipt of food items for storage;   a polyurethane elastomer positioned on a surface of the inner liner; and   a polyurethane foam disposed within the cavity between the outer case and the inner liner, the polyurethane foam contacting the polyurethane elastomer, the inner liner and the outer case within the cavity.   
     
     
         12 . The appliance of  claim 11 , wherein the inner liner comprises a first portion and a second portion, the first and second portions of the inner liner mounted to each other, the first and second portions of the inner liner defining a seam therebetween, the polyurethane elastomer positioned on the inner liner at the seam between the first and second portions of the inner liner such that the polyurethane elastomer is disposed between the polyurethane foam and the seam between the first and second portions of the inner liner. 
     
     
         13 . The appliance of  claim 12 , wherein the first and second potions of the inner liner define a fresh food chamber. 
     
     
         14 . The appliance of  claim 12 , wherein the first portion of the inner liner defines a fresh food chamber and the second potion of the inner liner defines a freezer chamber. 
     
     
         15 . The appliance of  claim 11 , wherein the inner liner defines an opening that extends between the interior volume of the inner liner and the polyurethane elastomer, the polyurethane elastomer positioned on the inner liner at the opening of the inner liner such that the polyurethane elastomer is disposed between the polyurethane foam and the opening of the inner liner. 
     
     
         16 . The appliance of  claim 11 , further comprising a rear panel mounted to the outer case such that the rear panel and the inner liner are spaced apart from each other, the inner liner, the outer case and the rear panel defining the cavity therebetween. 
     
     
         17 . The appliance of  claim 16 , wherein the polyurethane foam extends between the inner liner, the outer case and the rear panel within the cavity. 
     
     
         18 . The appliance of  claim 11 , wherein the polyurethane foam is a rigid closed cell polyurethane foam.