Refrigerator appliance and method of forming refrigerator appliance using ultrasonic welding

A method of manufacturing a refrigerator appliance, comprising:

• a providing step of providing:
• a liner that defines a compartment for storing food items and an aperture extending through the liner, the liner including liner contact structure, and
• a refrigerator component for attachment to the liner, the refrigerator component including component contact structure,
• wherein the liner and refrigerator component comprise the same type of plastic, the type being one of polyethylene terephthalate, high-density polyethylene, polyvinyl chloride, low-density Polyethylene, polypropylene, and polystyrene;
• a staging step that includes arranging the liner and refrigerator component such that the liner contact structure and component contact structure are in direct contact with each other under pressure and an interface of the component contact structure and liner contact structure circumscribes the aperture, wherein the liner and refrigerator component as arranged form a staged assembly;
• and
• a welding step that includes applying ultrasonic energy to the staged assembly to weld the liner and refrigerator component together at the interface of the component contact structure and liner contact structure, wherein the liner and refrigerator component as welded together form a liner assembly,
• wherein a hermetic seal is formed at the interface of the liner and refrigerator component by the welding step, wherein the hermetic seal is continuous and extends about an entire perimeter of the aperture.

A refrigerator appliance comprising:

• a liner assembly including a liner defining a compartment for storing food items and an aperture extending through the liner, and a refrigerator component welded to the liner via ultrasonic welding, wherein the liner and refrigerator component comprise the same type of plastic, the type being one of polyethylene terephthalate, high-density polyethylene, polyvinyl chloride, low-density Polyethylene, polypropylene, and polystyrene;
• an outer shell that surrounds the liner assembly;
• and
• foam insulation provided between the liner assembly and outer shell,
• wherein a hermetic seal is formed between the liner and refrigerator component by the ultrasonic welding, wherein the hermetic seal is continuous and extends about an entire perimeter of the aperture.

A liner assembly suitable for a refrigerator appliance, the liner assembly comprising:

• a liner defining a compartment for storing food items and an aperture extending through the liner;
• and
• a refrigerator component welded to the liner via ultrasonic welding,
• wherein the liner and refrigerator component comprise the same type of plastic, the type being one of polyethylene terephthalate, high-density polyethylene, polyvinyl chloride, low-density Polyethylene, polypropylene, and polystyrene, and
• wherein a hermetic seal is formed between the liner and refrigerator component by the ultrasonic welding, wherein the hermetic seal is continuous and extends about an entire perimeter of the aperture.