Abstract: The development trend of refrigerator towards thin foam layer and large volume has aggravated the problem of poor foam filling. It is an effective way to optimize the density distribution by regulating the foam flow with the diversion structure. However, it is difficult to directly observe the foaming process, resulting in the determination of the scheme relying on repeated tests, which is inefficient and costly. The simulation method can be used to design the scheme in the product design stage, improve the R&D efficiency and reduce the test cost. Firstly, a foaming simulation model of a box with upper and lower structure was built under the condition of diversion, and the error between the measured and simulated average density in each area of the box was less than 5%. Furthermore, the simulation and optimization of the diversion structure are carried out. Finally, through experimental verification, the foam density range of the optimized scheme was reduced by 10%, and the foam density uniformity was significantly improved.

Key words: Foaming simulation, Diversion structure, Optimized design, Density uniformity