The Door-in-a-Door Refrigerator Door
The Door-in-a-Door, or Countermaker Door, is a small access door mounted in the main refrigerator compartment door of a new thirty cubic foot consumer refrigerator. In the past, such units have been made of multiple injection molded components, including the two door skins. Spencer Industries worked with the customer to develop a new twin sheet formed version of this product that greatly reduced the number of component parts and the overall cost, while yielding a product that was as aesthetically pleasing and functional as its predecessor.
Produced from coextruded ABS, these units are twin sheet formed in three colors, (shown on the left): white, almond, and black.
Refrigerator Door-In-A-Door Forming Process
During the twin sheet forming process, a three piece injection molded internal hinge assembly is inserted by means of a pick and place robot. Once the twin sheet process is completed, the doors are then CNC trimmed and transported to our Assembly Division.
The final product has been foam filled for insulation and structure and multiple components, including frame bezel, gasket, handle, handle latch assembly and hinge assemblies have all been mounted to the door. The door assembly is then put through rigid testing and arrives at the customer's assembly line as a completed unit, ready for final assembly to the refrigerator.