Manufacturing method of panel, panel, and air conditioner having same

Abstract

This manufacturing method of a panel may comprise the steps of: perforating a steel sheet to form a plurality of holes in the steel sheet; de-burring the steel sheet; plating the de-burred steel sheet; and forming a film on the plated steel sheet.

Description

Method for manufacturing a panel, panel and air conditioner including the same

[0001] The present disclosure relates to a method for manufacturing a panel, a panel, and an air conditioner including the same, and more particularly, to a method for manufacturing a panel with improved corrosion resistance, a panel, and an air conditioner including the same.

[0002] An air conditioner is a device that uses a refrigeration cycle to regulate temperature, humidity, and airflow to a level suitable for human activity. Air conditioners can also remove dust and other contaminants from the air.

[0003] An air conditioner may include an indoor unit, an outdoor unit, and a refrigerant pipe connecting the indoor and outdoor units and circulating refrigerant.

[0004] Air conditioners can be classified into separate types that have an indoor unit placed indoors and an outdoor unit placed outdoors, and integrated types that have both indoor and outdoor units placed in one housing.

[0005] One aspect of the present disclosure may provide a method for manufacturing a panel, a panel, and an air conditioner including the same.

[0006] The problems to be solved by the present invention are not limited to the problems mentioned above, and other technical problems not mentioned can be clearly understood by a person having ordinary skill in the technical field to which the present invention belongs from the description below.

[0007] A method for manufacturing a panel according to one aspect of the present disclosure may include a step of forming a plurality of holes in a steel plate by punching the steel plate, a step of deburring the steel plate, a step of plating the deburred steel plate, and a step of forming a film on the plated steel plate.

[0008] According to one aspect of the present disclosure, a panel for an air conditioner including a plurality of holes for discharging air may include a galvanized steel sheet having the plurality of holes, a galvanized layer on a surface of the galvanized steel sheet, a chromate film layer on the surface of the galvanized layer, and a powder coating layer on the surface of the chromate film layer.

[0009] An air conditioner according to one aspect of the present disclosure comprises a panel including a housing, a heat exchanger disposed inside the housing to exchange heat with air introduced into the housing, and a plurality of holes formed to discharge the heat-exchanged air, wherein the plurality of holes have a diameter of 0.6 mm or more and 1 mm or less, and the panel may include a zinc-plated layer on a surface of a zinc-plated steel sheet, a chromate film layer on a surface of the zinc-plated layer, and a powder coating layer on a surface of the chromate film layer.

[0010] According to the idea of ​​the present disclosure, a method for manufacturing a panel (40) may include a step (S1) of forming a plurality of holes in a steel plate by punching the steel plate, a step (S2) of deburring the steel plate, a step (S3) of plating the deburred steel plate, and a step (S4) of forming a film on the plated steel plate. In this way, by removing burrs generated during the punching process of the steel plate, plating the same, and then forming a film, an additional electrodeposition coating process can be omitted, which not only reduces process costs but also prevents rust generated due to burrs, thereby improving the corrosion resistance of the panel (40).

[0011] In addition, according to the idea of ​​the present disclosure, the panel (40) may include a galvanized steel plate (2) having a plurality of holes for discharging air, a galvanized layer (3) on the surface of the galvanized steel plate (2), a chromate film layer (4) on the surface of the galvanized layer (3), and a powder coating layer (5) on the surface of the chromate film layer (4). In this way, by forming a film after plating the steel plate, corrosion resistance can be improved, and the appearance of the panel (40) applied to the air conditioner (1) can be maintained and corrosion can be prevented.

[0012] In addition, according to the idea of ​​the present disclosure, an air conditioner (1) includes a housing (10), a heat exchanger (30) disposed inside the housing (10) to exchange heat with air introduced into the housing (10); and a panel (40) having a plurality of holes formed to discharge the heat-exchanged air, wherein the plurality of holes have a diameter of 0.6 mm or more and 1 mm or less, and the panel (40) may include a zinc-plated layer (3) on a surface of a zinc-plated steel sheet (2), a chromate film layer (4) on a surface of the zinc-plated layer (3), and a powder coating layer (5) on a surface of the chromate film layer (4). In this way, by controlling the microscopic hole size of the panel (40) applied to the air conditioner (1), the noise of the air conditioner (1) is minimized, and the air volume is controlled so that the wind does not directly reach the user, while ensuring cooling efficiency. In addition, by improving the corrosion resistance of these multiple microscopic holes, the maintenance and management of the air conditioner (1) becomes easier, and the cost for managing the air conditioner (1) can be reduced.

[0013] FIG. 1 is a flowchart illustrating a method for manufacturing a panel according to one embodiment of the present invention.

[0014] Figure 2 is a drawing showing an air conditioner panel with a discharge hole and a cross-section (A-A') of the panel.

[0015] Figure 3 is a cross-sectional view of a panel applied to a conventional air conditioner.

[0016] Figure 4 is a cross-sectional view of a panel manufactured according to one embodiment of the present invention.

[0017] Fig. 5 is an optical microscope photograph at 200x magnification showing a burr formed on the surface of a steel plate used in an air conditioner panel according to a conventional invention after punching.

[0018] FIG. 6 is an optical microscope photograph taken at 200x magnification of the surface of a panel manufactured according to one embodiment of the present invention.

[0019] Figure 7 is a photograph of a 10-cycle salt spray test performed on a panel applied to a conventional air conditioner.

[0020] FIG. 8 is a photograph showing a panel manufactured according to one embodiment of the present invention after 13 cycles of salt spray testing.

[0021] Figure 9 is a perspective view of an air conditioner according to one embodiment of the present invention.

[0022] Fig. 10 is a drawing showing the air conditioner illustrated in Fig. 9 in an exploded view.

[0023] It should be understood that the various embodiments and terms used in this document are not intended to limit the technical features described in this document to specific embodiments, but rather to encompass various modifications, equivalents, or alternatives of the embodiments.

[0024] In connection with the description of the drawings, similar reference numerals may be used for similar or related components.

[0025] The singular form of a noun corresponding to an item may include one or more of said items, unless the relevant context clearly indicates otherwise.

[0026] In this document, each of the phrases "A or B", "at least one of A and B", "at least one of A or B", "A, B, or C", "at least one of A, B, and C", and "at least one of A, B, or C" may include any one of the items listed together in that phrase, or all possible combinations thereof.

[0027] The term "and / or" includes any combination of a plurality of related described elements or any one of a plurality of related described elements.

[0028] Terms such as "first," "second," or "first" or "second" may be used simply to distinguish one component from another and do not qualify the components in any other respect (e.g., importance or order).

[0029] When a component (e.g., a first component) is referred to as being "coupled" or "connected" to another component (e.g., a second component), with or without the terms "functionally" or "communicatively," it means that the component can be connected to the other component directly (e.g., wired), wirelessly, or through a third component.

[0030] The terms "include" or "have" are intended to specify the presence of a feature, number, step, operation, component, part or combination thereof described in this document, but do not preclude the presence or addition of one or more other features, numbers, steps, operations, components, parts or combinations thereof.

[0031] When a component is said to be “connected,” “coupled,” “supported,” or “in contact with” another component, this includes not only cases where the components are directly connected, coupled, supported, or in contact, but also cases where the components are indirectly connected, coupled, supported, or in contact through a third component.

[0032] When we say that a component is "on" another component, this includes not only cases where the component is in contact with the other component, but also cases where there is another component between the two components.

[0033] An air conditioner according to various embodiments is a device that performs functions such as air purification, ventilation, humidity control, cooling or heating in an air-conditioned space (hereinafter referred to as “indoor”), and means a device equipped with at least one of these functions.

[0034] In one embodiment, an air conditioner may include a heat pump device to perform a cooling function or a heating function. The heat pump device may include a refrigeration cycle in which a refrigerant circulates along a compressor, a first heat exchanger, an expansion device, and a second heat exchanger. All components of the heat pump device may be housed in a single housing forming the exterior of the air conditioner, such as a window air conditioner or a portable air conditioner. On the other hand, some components of the heat pump device may be housed separately in multiple housings forming a single air conditioner, such as a wall-mounted air conditioner, a stand-alone air conditioner, and a system air conditioner.

[0035] An air conditioner including a plurality of housings may include at least one outdoor unit installed outdoors and at least one indoor unit installed indoors. For example, the air conditioner may be configured such that one outdoor unit and one indoor unit are connected via a refrigerant pipe. For example, the air conditioner may be configured such that one outdoor unit is connected to two or more indoor units via refrigerant pipes. For example, the air conditioner may be configured such that two or more outdoor units and two or more indoor units are connected via a plurality of refrigerant pipes.

[0036] The outdoor unit can be electrically connected to the indoor unit. For example, information (or commands) for controlling the air conditioner can be input through an input interface provided on the outdoor or indoor unit, and the outdoor and indoor units can operate simultaneously or sequentially in response to user input.

[0037] The air conditioner may include an outdoor heat exchanger provided in the outdoor unit, an indoor heat exchanger provided in the indoor unit, and a refrigerant pipe connecting the outdoor heat exchanger and the indoor heat exchanger.

[0038] An outdoor heat exchanger can utilize a phase change (e.g., evaporation or condensation) of the refrigerant to exchange heat between the refrigerant and the outdoor air. For example, while the refrigerant condenses in the outdoor heat exchanger, it releases heat to the outdoor air, and while the refrigerant flowing in the outdoor heat exchanger evaporates, it absorbs heat from the outdoor air.

[0039] Indoor units are installed indoors. For example, indoor units can be categorized into ceiling-mounted, stand-alone, and wall-mounted types depending on their placement. For example, ceiling-mounted indoor units can be categorized into four-way, one-way, and duct-type indoor units depending on how air is discharged.

[0040] Similarly, an indoor heat exchanger can utilize the phase change of the refrigerant (e.g., evaporation or condensation) to exchange heat between the refrigerant and indoor air. For example, while the refrigerant evaporates in the indoor unit, the refrigerant can absorb heat from the indoor air. The cooled indoor air can then be blown through the cooled indoor heat exchanger, thereby cooling the room. Furthermore, while the refrigerant condenses in the indoor heat exchanger, the refrigerant can release heat to the indoor air. By blowing the heated indoor air through the high-temperature indoor heat exchanger, the room can be heated.

[0041] That is, the air conditioner performs a cooling or heating function through a phase change process of the refrigerant circulating between the outdoor heat exchanger and the indoor heat exchanger. To circulate the refrigerant, the air conditioner may include a compressor that compresses the refrigerant. The compressor can suck in refrigerant gas through the suction port and compress the refrigerant gas. The compressor can discharge the high-temperature and high-pressure refrigerant gas through the discharge port. The compressor may be placed inside the outdoor unit.

[0042] The refrigerant may circulate through the refrigerant pipes in the order of a compressor, an outdoor heat exchanger, an expansion device, and an indoor heat exchanger, or in the order of a compressor, an indoor heat exchanger, an expansion device, and an outdoor heat exchanger.

[0043] For example, if an air conditioner has one outdoor unit and one indoor unit directly connected through a refrigerant pipe, the refrigerant may be arranged to circulate between one outdoor unit and one indoor unit through the refrigerant pipe.

[0044] For example, in an air conditioner, if one outdoor unit is connected to two or more indoor units via refrigerant pipes, the refrigerant can flow to multiple indoor units via refrigerant pipes branching from the outdoor unit. The refrigerant discharged from the multiple indoor units can be combined and circulated to the outdoor unit. For example, multiple indoor units can be directly connected in parallel to a single outdoor unit via separate refrigerant pipes.

[0045] Multiple indoor units can operate independently, each according to a user-defined operating mode. That is, some indoor units can operate in cooling mode, while others operate in heating mode. In this case, the refrigerant can be selectively introduced into each indoor unit at either high or low pressure along a designated circulation path via a flow-through valve, described later, and then discharged to the outdoor unit for circulation.

[0046] For example, when an air conditioner has two or more outdoor units and two or more indoor units connected through multiple refrigerant pipes, the refrigerant discharged from the multiple outdoor units may merge and flow through a single refrigerant pipe, then branch off again at some point and flow into multiple indoor units.

[0047] Multiple outdoor units may all be operated, or at least some may not be operated, depending on the operating load of the multiple indoor units. In this case, the refrigerant may be introduced into the outdoor unit, which is selectively operated, through a flow switching valve and circulated there. The air conditioner may include an expansion device to reduce the pressure of the refrigerant flowing into the heat exchanger. For example, the expansion device may be located within the indoor unit, the outdoor unit, or both.

[0048] An expansion device can, for example, utilize a throttling effect to lower the temperature and pressure of the refrigerant. The expansion device may include an orifice capable of reducing the cross-sectional area of ​​the flow path. Refrigerant passing through the orifice may experience a decrease in temperature and pressure.

[0049] The expansion device may be implemented as, for example, an electronic expansion valve capable of controlling the opening ratio (the ratio of the cross-sectional area of ​​the valve's flow path when partially open to the cross-sectional area of ​​the valve's flow path when fully open). Depending on the opening ratio of the electronic expansion valve, the amount of refrigerant passing through the expansion device can be controlled.

[0050] The air conditioner may further include a flow diverter valve positioned along the refrigerant circulation path. The flow diverter valve may include, for example, a four-way valve. The flow diverter valve may determine the refrigerant circulation path depending on the indoor unit's operating mode (e.g., cooling operation or heating operation). The flow diverter valve may be connected to the discharge port of the compressor.

[0051] The air conditioner may include an accumulator. The accumulator may be connected to the suction port of the compressor. The accumulator may receive low-temperature, low-pressure refrigerant vaporized in an indoor heat exchanger or an outdoor heat exchanger.

[0052] The accumulator can separate the refrigerant liquid from the refrigerant gas when a refrigerant mixture of refrigerant liquid and refrigerant gas is introduced, and provide the refrigerant gas from which the refrigerant liquid has been separated to the compressor.

[0053] An outdoor fan may be installed near the outdoor heat exchanger. The outdoor fan may blow outdoor air to the outdoor heat exchanger to promote heat exchange between the refrigerant and the outdoor air.

[0054] The outdoor unit of the air conditioner may include at least one sensor. For example, the sensor of the outdoor unit may be provided as an environmental sensor. The outdoor unit sensor may be positioned at any location inside or outside the outdoor unit. For example, the outdoor unit sensor may include a temperature sensor for detecting the air temperature around the outdoor unit, a humidity sensor for detecting the air humidity around the outdoor unit, a refrigerant temperature sensor for detecting the refrigerant temperature of a refrigerant pipe passing through the outdoor unit, or a refrigerant pressure sensor for detecting the refrigerant pressure of a refrigerant pipe passing through the outdoor unit.

[0055] An outdoor unit of an air conditioner may include an outdoor unit communication unit. The outdoor unit communication unit may be configured to receive a control signal from a control unit of an indoor unit of the air conditioner, which will be described later. The outdoor unit may control the operation of a compressor, an outdoor heat exchanger, an expansion device, a flow switching valve, an accumulator, or an outdoor fan based on the control signal received through the outdoor unit communication unit. The outdoor unit may transmit a sensing value detected by an outdoor unit sensor to the control unit of the indoor unit through the outdoor unit communication unit.

[0056] The indoor unit of the air conditioner may include a housing, a blower for circulating air into or out of the housing, and an indoor heat exchanger for exchanging heat with air flowing into the interior of the housing.

[0057] The housing may include an intake port through which indoor air may be drawn into the interior of the housing.

[0058] The indoor unit of the air conditioner may include a filter that is provided to filter foreign substances in the air that flows into the housing through the intake port.

[0059] The housing may include an exhaust port. Air flowing within the housing may be discharged to the exterior of the housing through the exhaust port.

[0060] The housing of the indoor unit may be provided with an airflow guide that guides the direction of air discharged through the exhaust port. For example, the airflow guide may include blades positioned above the exhaust port. For example, the airflow guide may include an auxiliary fan for controlling the exhaust airflow. However, the airflow guide is not limited thereto and may be omitted.

[0061] An indoor heat exchanger and a blower may be provided inside the housing of the indoor unit, which are arranged on a path connecting the intake and exhaust ports.

[0062] Blowers may include indoor fans and fan motors. For example, indoor fans may include axial fans, diffusion fans, crossflow fans, and centrifugal fans.

[0063] An indoor heat exchanger may be positioned between the blower and the exhaust, or between the intake and the blower. The indoor heat exchanger may absorb heat from air drawn in through the intake or transfer heat to the air drawn in through the intake. The indoor heat exchanger may include heat exchange tubes through which refrigerant flows, and heat exchange fins in contact with the heat exchange tubes to increase the heat transfer surface area.

[0064] The indoor unit of the air conditioner may include a drain tray positioned below the indoor heat exchanger to collect condensate generated in the indoor heat exchanger. The condensate collected in the drain tray may be drained to the outside through a drain hose. The drain tray may be provided to support the indoor heat exchanger.

[0065] The indoor unit of the air conditioner may include an input interface. The input interface may include any type of user input means, including buttons, switches, a touch screen, and / or a touch pad. The user can directly input setting data (e.g., desired indoor temperature, operating mode settings for cooling / heating / dehumidification / air purification, outlet selection settings, and / or air flow settings) through the input interface.

[0066] The input interface may also be connected to an external input device. For example, the input interface may be electrically connected to a wired remote controller. The wired remote controller may be installed at a specific location in an indoor space (e.g., a portion of a wall). A user may input configuration data regarding the operation of the air conditioner by operating the wired remote controller. Electrical signals corresponding to the configuration data obtained through the wired remote controller may be transmitted to the input interface. In addition, the input interface may include an infrared sensor. A user may remotely input configuration data regarding the operation of the air conditioner using a wireless remote controller. The configuration data input through the wireless remote controller may be transmitted to the input interface as an infrared signal.

[0067] Additionally, the input interface may include a microphone. A user's voice command may be acquired through the microphone. The microphone may convert the user's voice command into an electrical signal and transmit the converted electrical signal to an indoor unit control unit. The indoor unit control unit may control components of the air conditioner to execute a function corresponding to the user's voice command. Setting data acquired through the input interface (e.g., desired indoor temperature, operation mode settings for cooling / heating / dehumidification / air purification, outlet selection settings, and / or air volume settings) may be transmitted to the indoor unit control unit, which will be described later. In one example, the setting data acquired through the input interface may be transmitted externally, i.e., to an outdoor unit or a server, through an indoor unit communication unit, which will be described later.

[0068] The indoor unit of the air conditioner may include a power module. The power module may be connected to an external power source to supply power to the components of the indoor unit.

[0069] An indoor unit of an air conditioner may include an indoor unit sensor. The indoor unit sensor may be an environmental sensor positioned in a space inside or outside the housing. For example, the indoor unit sensor may include one or more temperature sensors and / or humidity sensors positioned in a predetermined space inside or outside the housing of the indoor unit. For example, the indoor unit sensor may include a refrigerant temperature sensor for detecting a refrigerant temperature of a refrigerant pipe passing through the indoor unit. For example, the indoor unit sensor may include respective refrigerant temperature sensors for detecting the inlet, middle, and / or outlet temperatures of the refrigerant pipe passing through the indoor heat exchanger.

[0070] For example, each environmental information detected by an indoor unit sensor can be transmitted to the indoor unit control unit described later or transmitted externally through the indoor unit communication unit described later.

[0071] The indoor unit of the air conditioner may include an indoor unit communication unit. The indoor unit communication unit may include at least one of a short-range communication module and a long-range communication module. The indoor unit communication unit may include at least one antenna for wireless communication with other devices. The outdoor unit may include an outdoor unit communication unit. The outdoor unit communication unit may also include at least one of a short-range communication module and a long-range communication module.

[0072] The short-range wireless communication module may include, but is not limited to, a Bluetooth communication module, a BLE (Bluetooth Low Energy) communication module, a near field communication module, a WLAN (Wi-Fi) communication module, a Zigbee communication module, an infrared (IrDA, infrared Data Association) communication module, a WFD (Wi-Fi Direct) communication module, an UWB (ultrawideband) communication module, an Ant+ communication module, a microwave (uWave) communication module, etc.

[0073] The long-distance communication module may include a communication module that performs various types of long-distance communication and may include a mobile communication unit. The mobile communication unit transmits and receives wireless signals with at least one of a base station, an external terminal, and a server on a mobile communication network.

[0074] The indoor unit communication unit can communicate with external devices such as servers, mobile devices, and other home appliances through a nearby access point (AP). The access point (AP) can connect a local area network (LAN) to which the air conditioner or user device is connected to a wide area network (WAN) to which the server is connected. The air conditioner or user device can be connected to the server through the wide area network (WAN). The indoor unit of the air conditioner may include an indoor unit control unit that controls components of the indoor unit, including a blower, etc. The outdoor unit of the air conditioner may include an outdoor unit control unit that controls components of the outdoor unit, including a compressor, etc. The indoor unit control unit can communicate with the outdoor unit control unit through the indoor unit communication unit and the outdoor unit communication unit. The outdoor unit communication unit can transmit control signals generated by the outdoor unit control unit to the indoor unit communication unit, or transmit control signals transmitted from the indoor unit communication unit to the outdoor unit control unit. In other words, the outdoor unit and the indoor unit can communicate bidirectionally. The outdoor unit and the indoor unit can transmit and receive various signals generated during the operation of the air conditioner.

[0075] The outdoor unit control unit can be electrically connected to components of the outdoor unit and can control the operation of each component. For example, the outdoor unit control unit can adjust the frequency of the compressor and control the flow switching valve to change the circulation direction of the refrigerant. The outdoor unit control unit can adjust the rotation speed of the outdoor fan. In addition, the outdoor unit control unit can generate a control signal to adjust the opening degree of the expansion valve. Under the control of the outdoor unit control unit, the refrigerant can circulate along a refrigerant circulation circuit including the compressor, the flow switching valve, the outdoor heat exchanger, the expansion valve, and the indoor heat exchanger.

[0076] The various temperature sensors included in the outdoor and indoor units can transmit electrical signals corresponding to the detected temperatures to the outdoor unit control unit and / or the indoor unit control unit. For example, the humidity sensors included in the outdoor and indoor units can transmit electrical signals corresponding to the detected humidity to the outdoor unit control unit and / or the indoor unit control unit.

[0077] The indoor unit control unit can obtain user input from a user device, including a mobile device, via the indoor unit communication unit, and can obtain user input directly through the input interface or via a remote controller. The indoor unit control unit can control components of the indoor unit, including a blower, in response to the received user input. The indoor unit control unit can transmit information regarding the received user input to the outdoor unit control unit of the outdoor unit.

[0078] The outdoor unit control unit can control the components of the outdoor unit, including the compressor, based on information regarding user input received from the indoor unit. For example, when a control signal corresponding to a user input for selecting an operation mode, such as cooling operation, heating operation, ventilation operation, defrosting operation, or dehumidification operation, is received from the indoor unit, the outdoor unit control unit can control the components of the outdoor unit so that the air conditioner performs an operation corresponding to the selected operation mode.

[0079] The outdoor unit control unit and the indoor unit control unit may each include a processor and a memory. The indoor unit control unit may include at least one first processor and at least one first memory, and the outdoor unit control unit may include at least one second processor and at least one second memory.

[0080] The memory can store / remember various information necessary for the operation of the air conditioner. The memory can store instructions, applications, data, and / or programs necessary for the operation of the air conditioner. For example, the memory can store various programs for cooling, heating, dehumidifying, and / or defrosting operations of the air conditioner. The memory can include volatile memory, such as Static Random Access Memory (S-RAM) and Dynamic Random Access Memory (DRAM), for temporarily storing data. In addition, the memory can include nonvolatile memory, such as Read Only Memory (ROM), Erasable Programmable Read Only Memory (EPROM), and Electrically Erasable Programmable Read Only Memory (EEPROM), for storing data for a long period of time.

[0081] The processor can generate control signals for controlling the operation of the air conditioner based on instructions, applications, data, and / or programs stored in memory. The processor, as hardware, may include logic circuits and arithmetic circuits. The processor can process data according to programs and / or instructions provided from the memory and generate control signals based on the processing results. The memory and the processor may be implemented as a single control circuit or as multiple circuits.

[0082] An indoor unit of an air conditioner may include an output interface. The output interface is electrically connected to the indoor unit control unit and can output information related to the operation of the air conditioner under the control of the indoor unit control unit. For example, information such as an operating mode selected by a user input, wind direction, wind volume, and temperature may be output. Additionally, the output interface may output sensing information obtained from an indoor unit sensor or an outdoor unit sensor, as well as warning / error messages.

[0083] The output interface may include a display and a speaker. The speaker, as an audio device, can output various sounds. The display may display information input by the user or information provided to the user using various graphic elements. For example, operation information of an air conditioner may be displayed as at least an image or text. The display may also include an indicator that provides specific information. The display may include a liquid crystal display panel (LCD), a light emitting diode panel (LED), an organic light emitting diode panel (OLED), a micro LED panel, and / or a plurality of LEDs.

[0084] The drawings are described in detail below.

[0085] FIG. 1 is a flowchart showing a method for manufacturing a panel according to one embodiment of the present invention. Referring to FIG. 1, a panel according to one embodiment of the present invention may be manufactured through a step (S1) of forming a plurality of holes in a steel plate by punching a steel plate, a step (S2) of deburring the steel plate, a step (S3) of plating the deburred steel plate, a step (S4) of forming a film on the plated steel plate, a step (S5) of primarily drying the steel plate on which the film has been formed, a step (S6) of painting the primarily dried steel plate, and a step (S7) of secondarily drying the painted steel plate. However, the present invention is not limited to these steps, and a degreasing step such as ultrasonic degreasing and a washing step may be additionally included between the punching step (S1) and the deburring step (S2).

[0086] Fig. 2 is a drawing showing a panel of an air conditioner provided with a discharge hole and a cross-section (A-A') of the panel, and Fig. 3 is a cross-sectional view of a panel applied to a conventional air conditioner.

[0087] Referring to Fig. 2, in the case of an air conditioner equipped with a discharge hole, numerous discharge holes are formed in the panel by punching. Referring to Fig. 3, it can be seen that numerous burrs are generated on the galvanized steel sheet after the punching step (S1), and in the case of panels applied to conventional air conditioners, it can be seen that the burrs are treated by covering the burrs with an electroplating coating rather than removing the burrs.

[0088] Fig. 4 is a cross-sectional view of a panel (40) manufactured according to one embodiment of the present invention. Referring to Fig. 4, in the panel (40) according to one embodiment of the present invention, after the step (S1) of forming a plurality of holes in a steel plate by punching the steel plate, in the step (S2) of deburring the steel plate, it can be confirmed that a zinc-plated layer (3), a chromate film layer (4), and a powder coating layer (5) are formed on the zinc-plated steel plate (2) from which burrs have been removed by immersing the zinc-plated steel plate (2) in an acid solution.

[0089] Fig. 5 is an optical microscope photograph taken at 200x magnification showing burrs formed on the surface of a steel plate used in an air conditioner panel according to a conventional invention after punching. Referring to Fig. 5, it can be confirmed that burrs were formed on the surface of the steel plate after punching. In the conventional invention, such burrs were covered by electrodeposition coating, but even with this additional coating process, not only could the burrs not be completely removed, but there was also the problem of increased production costs due to the cost required for electrodeposition coating.

[0090] Fig. 6 is an optical microscope photograph taken at 200x magnification of the surface of a panel (40) manufactured according to one embodiment of the present invention. Referring to Fig. 6, unlike Fig. 5, it can be seen that not only has a burr formed on the steel plate been removed by chemical deburring, but also a plating layer can be formed on the steel plate to a thickness of 0.015 mm to 0.021 mm, and a thin film is formed on the surface of the plating layer.

[0091] Fig. 7 is a photograph of a panel applied to a conventional air conditioner after 10 cycles of a salt spray test. Referring to Fig. 7, it can be confirmed that rust occurs on the steel plate when the panel applied to a conventional air conditioner is subjected to 10 cycles of a salt spray test.

[0092] Fig. 8 is a photograph showing a panel (40) manufactured according to one embodiment of the present invention subjected to 13 cycles of a salt spray test. Referring to Fig. 8, it can be confirmed that no rust occurs on the steel plate even when the panel manufactured according to one embodiment of the present invention is subjected to 13 cycles of a salt spray test.

[0093] FIG. 9 is a drawing showing an air conditioner (1) to which a panel (40) manufactured according to one embodiment of the present invention is applied, and FIG. 10 is an exploded view of the air conditioner (1) shown in FIG. 9.

[0094] The above drawings have been described. Below, with reference to the drawings, a method for manufacturing a panel according to various embodiments will be described in detail.

[0095] A method for manufacturing a panel (40) according to one embodiment of the present invention may include a step (S1) of forming a plurality of holes in a steel plate by punching the steel plate, a step (S2) of deburring the steel plate, a step (S3) of plating the deburred steel plate, and a step (S4) of forming a film on the plated steel plate, and may further include a step (S5) of primarily drying the steel plate on which the film has been formed, a step (S6) of painting the primarily dried steel plate, and a step (S7) of secondarily drying the painted steel plate.

[0096] The above punching step (S1) can form multiple holes in a steel plate using a press device. During this hole forming process, burrs are created on one surface of the steel plate, and these burrs not only deteriorate the appearance of the steel plate but also can induce corrosion, so special treatment is required. A burr is generated during the processing and refers to unintended protrusions and residues during processing, and in particular, refers to deformations such as irregular and sharp shapes during metal processing. In the present invention, a burr can be used with the same meaning as a burr or a burr, and deburring refers to a process of removing such burrs.

[0097] The present invention may further include a step of washing away various deposits or dusts present on the surface of the steel plate by additionally including a degreasing and water washing step after the punching step (S1), and at this time, a method such as ultrasonic degreasing may be used.

[0098] After the above punching step (S1), the impurities remaining in the steel plate can be removed through a deburring step (S2) of the steel plate, and the burr generated in the punching step (S1) can be removed.

[0099] After the step (S2) of deburring the steel plate, a step (S3) of plating the steel plate may be performed, and at this time, electroplating may be performed by immersing the steel plate in a zinc plating solution or a zinc alloy plating solution containing 91% or more and 97% or less of zinc by weight and 3% or more and 9% or less of nickel. Here, electroplating means inserting the steel plate into the cathode and applying voltage so that zinc ions from the anode are deposited on the product.

[0100] In addition, the plating step (S3) may include plating the deburred steel sheet, and the plating layer formed in the plating step (S3) may have an average thickness of 15 µm or more and 20 µm or less. In consideration of the size of the burr, the average thickness of the plating layer may be limited as described above in order to uniformly process the uneven portion of the steel sheet surface.

[0101] In a method for manufacturing a panel (40) according to one embodiment of the present invention, the steel sheet to be deburred may include a galvanized steel sheet (2). In the case of an air conditioner (1), a hot-dip galvanized steel sheet is typically applied, but an electro-galvanized steel sheet may also be applied, and steel sheets of various materials may be applied within a range that can achieve the purpose of the present invention. As described above, by using a galvanized steel sheet (2) in the panel (40), the steel sheet can be prevented from being corroded or damaged during transportation or storage, etc.

[0102] A method for manufacturing a panel (40) according to one embodiment of the present invention may include, in the deburring step (S2), immersing the steel plate in an acidic solution in which at least one acid selected from the group consisting of HCl, HNO3, H2SO4, and HF is diluted in water, and the acidic solution may include HCl and H2SO4, or a mixture thereof, and the acidic solution may include HCl of 10% or more and H2SO4 of 20% or less by weight and H2SO4 of 5% or more and H2SO4 of 10% or less by weight. Here, HCl and H2SO4 refer to pure HCl and pure H2SO4 having a purity of 99% or more, and when the acidic solution is manufactured with the above mixing ratio, the efficiency of removing burrs or corrosion products of the steel plate generated in the punching step (S1) can be secured. In addition, when deburring is performed using an acid solution having the above ratio, burrs generated in numerous holes can be processed evenly and quickly, and the problem of reduced burr removal efficiency due to wear of a deburring tool such as sandpaper, as in mechanical deburring, can be solved.

[0103] In a method for manufacturing a panel (40) according to one embodiment of the present invention, the deburring step (S2) may be performed at a temperature of 30°C or more and 40°C or less for 5 minutes or more and 10 minutes or less. If the deburring step (S2) is performed for less than 5 minutes, burrs generated in numerous holes may not all be removed, which may cause corrosion, and if it is performed for more than 10 minutes, the steel plate may be damaged due to the acidic solution. Therefore, the deburring step (S2) may be limited to the time as described above.

[0104] A method for manufacturing a panel (40) according to one embodiment of the present invention may include, in the film forming step (S4), immersing the plated steel sheet in a trivalent chromium solution. At this time, a bluish-white trivalent chromium solution having excellent corrosion resistance may be used, and the film may be formed through chromate treatment by immersing the steel sheet for 1 minute to 5 minutes at a temperature of 15°C to 25°C. In the present invention, the film can prevent corrosion of the steel sheet when the paint for corrosion resistance and appearance is removed.

[0105] In a method for manufacturing a panel (40) according to one embodiment of the present invention, the first drying step (S5) can dry the steel sheet on which the film is formed at a temperature of 55°C or more and 65°C or less. This is because the chromate layer (4) is coated to a thickness of 1 μm or less, and if dried at a temperature exceeding 65°C, cracks may occur in the chromate layer (4), causing rust to occur. Therefore, the first drying step (S5) can be limited to the above range.

[0106] In a method for manufacturing a panel (40) according to one embodiment of the present invention, the coating step (S6) may be performed by powder coating the primarily dried steel plate with an epoxy-polyester hybrid powder coating. Here, there is no limitation on the powder coating method and coating material, but epoxy-polyester hybrid powder coating, which can generally be used for interior decoration or home appliances, may be applied, and an electrostatic coating method may be applied in which powder coating is sprayed with a spray gun to which voltage is applied so that it adheres to the product to which voltage is applied and is painted. However, the present invention is not limited to this electrostatic coating method, and various coating methods may be applied as long as the purpose of the present invention can be achieved and powder coating can be applied.

[0107] In a method for manufacturing a panel (40) according to one embodiment of the present invention, the second drying step (S7) can dry the painted steel sheet at a temperature of 180°C or higher and 200°C or lower. This corresponds to the drying conditions of powder coating (5). At this time, unlike general paint, in the case of powder coating in powder form, a method of attaching powder to the surface of a product using an electric current is required, and therefore, the scope of the second drying step (S7) is limited as described above so that the powder coating can be dissolved and painted on the surface of the product.

[0108] The method for manufacturing a panel (40) according to one embodiment of the present invention has been described above. Below, a panel (40) according to one embodiment of the present invention will be described.

[0109] According to one embodiment of the present invention, a panel (40) for an air conditioner including a plurality of holes for discharging air may include a galvanized steel sheet (2) having the plurality of holes, a galvanized layer (3) on a surface of the galvanized steel sheet, a chromate film layer (4) on the surface of the galvanized layer, and a powder coating layer (5) on the surface of the chromate film layer, wherein the galvanized layer (3) includes zinc, or zinc: 91% or more and 97% or less by weight and nickel: 3% or more and 9% or less, the chromate film layer (4) includes trivalent chromium, and the powder coating layer (5) may include an epoxy-polyester hybrid powder coating, and the average thickness of the galvanized layer (3) is 15 ㎛ or more and 20 ㎛ or less, and the average thickness of the chromate film layer (4) is more than 0 ㎛ and 1 ㎛. Below, the average thickness of the powder coating layer (5) may be 50 ㎛ or more and 80 ㎛ or less.

[0110] Here, the zinc plating layer (3) may be limited in average thickness as described above in consideration of the size of the burr in order to make the uneven portion of the steel plate surface uniform. In addition, the chromate film layer (4) may be limited in average thickness as described above in order to protect the zinc plating layer (3) and improve corrosion resistance, and the powder coating layer (5) may be limited in average thickness as described above in that if the average thickness is less than 50㎛, a coating film may not be formed when paint is sprayed, and if it exceeds 80㎛, the discharge hole of the panel (40) may become narrow or blocked, which may deteriorate the performance of the air conditioner. In the present invention, the average thickness means a value obtained by dividing the sum of the maximum thickness and the minimum thickness of each layer by 2.

[0111] The panel (40) according to one embodiment of the present invention has been described above. Hereinafter, an air conditioner (1) including a panel (40) according to one embodiment of the present invention will be described with reference to the drawings.

[0112] Fig. 9 is a perspective view of an air conditioner (1) according to one embodiment of the present invention. Fig. 10 is an exploded view of the air conditioner (1) illustrated in Fig. 9.

[0113] Referring to FIGS. 9 and 10, the air conditioner (1) may include a housing (10) forming an exterior, a blower unit (20) for circulating air into or out of the housing (10), and a heat exchanger (30) for exchanging heat with air flowing into the interior of the housing (10).

[0114] The housing (10) may include a case (11) in which a blower unit (20) and a heat exchanger (30) are mounted, and a front panel (16) covering the front of the case (11). The housing (10) may include a first intake port (12), a second intake port (15), a first discharge port (17), and a second discharge port (13).

[0115] The case (11) can form the rear surface, part of both sides, part of the upper surface, and the bottom surface of the air conditioner (1). The case (11) has an open front, and the open front surface can be covered by a front panel (16). In Fig. 2, the front panel (16) is illustrated as being provided to be detachable from the case (11), but the front panel (16) and the case (11) may also be formed integrally.

[0116] A first discharge port (17) may be formed on the front panel (16). The first discharge port (17) may be arranged on the front of the housing (10). The first discharge port (17) may penetrate the front panel (16). The first discharge port (17) may be formed on the upper portion of the front panel (16). The first discharge port (17) may be arranged at a position approximately facing the first intake port (12). Air that has been heat-exchanged inside the housing (10) may be discharged to the outside of the housing (10) through the first discharge port (17). The first discharge port (17) may discharge air introduced through the first intake port (12).

[0117] A panel support member (17a) that supports the panel (40) may be formed on a portion of the front panel (16) where the first discharge port (17) is formed. The panel support member (17a) may extend across the discharge port. The panel support member (17a) may support the back surface of the panel (40).

[0118] A first suction port (12) may be formed in the case (11). The first suction port (12) may penetrate the back surface of the case (11). The first suction port (12) may be formed at the upper portion of the back surface of the case (11). External air may be introduced into the interior of the housing (10) through the first suction port (12).

[0119] Although Fig. 10 illustrates that three first suction ports (12) are provided, the number of first suction ports (12) is not limited thereto and may be provided in various forms as needed. Although Fig. 10 illustrates that the first suction port (12) is formed in a circular shape, the shape of the first suction port (12) is not limited thereto and may be provided in various forms as needed.

[0120] A second suction port (15) may be formed in the case (11). The second suction port (15) may penetrate the back surface of the case (11). The second suction port (15) may be formed at the lower portion of the back surface of the case (11). The second suction port (15) may be formed at the lower side of the first suction port (12). External air may be introduced into the interior of the housing (10) through the second suction port (15).

[0121] As with the first suction port (12), the number and / or shape of the second suction port (15) can also be varied as needed.

[0122] A second discharge port (13) may be formed in the case (11). The second discharge port (13) may be arranged adjacent to the first discharge port (17). The second discharge port (13) may be arranged on at least one side of the case (11). The second discharge port (13) may penetrate the side of the case (11). The second discharge port (13) may be formed on an upper portion of the side of the case (11). The second discharge port (13) may be formed on both side surfaces corresponding to a portion of the housing (10) where the first discharge port (17) is formed.

[0123] The second discharge port (13) may extend along the vertical direction of the case (11). Air that has not undergone heat exchange inside the housing (10) may be discharged to the outside of the housing (10) through the second discharge port (13). The second discharge port (13) may be provided to discharge air drawn in through the second intake port (15).

[0124] The second discharge port (13) may be configured to mix the air discharged from the second discharge port (13) with the air discharged from the first discharge port (17). Specifically, a portion of the case (11) in which the second discharge port (13) is formed may include a guide curved portion that guides the air discharged from the second discharge port (13) so that the air discharged from the second discharge port (13) is mixed with the air discharged from the first discharge port (17).

[0125] The guide curved portion can guide the air discharged from the second discharge port (13) by the Coanda effect. That is, the air discharged through the second discharge port (13) can be discharged in a direction along the guide curved portion so as to be mixed with the air discharged from the first discharge port (17). When the second discharge port (13) is arranged on the side of the housing (10) and the first discharge port (17) is arranged on the front of the housing (10), the guide curved portion can be arranged to guide the air discharged through the second discharge port (13) forward.

[0126] A blade (61) may be provided on the second discharge port (13) to guide air discharged through the second discharge port (13). The blades (61) may be arranged continuously along the length of the second discharge port (13).

[0127] The air flow path connecting the first intake port (12) and the first outlet port (17) is called the first flow path, and the air flow path connecting the second intake port (15) and the second outlet port (13) is called the second flow path. Here, the first flow path and the second flow path can be separated. Accordingly, the air flowing through the first flow path and the air flowing through the second flow path may not mix.

[0128] Specifically, the first and second euros can be partitioned by a partition plate (18). The partition plate (18) can extend vertically inside the housing (10) in which the first blower unit (21) is arranged. The partition plate (18) can extend along the direction in which the second discharge port (13) is formed. The partition plate (18) can protrude convexly from the inner surface of the housing (10).

[0129] The air conditioner (1) can discharge air that has exchanged heat with the heat exchanger (30) through the first discharge port (17), and can discharge air that has not passed through the heat exchanger (30) through the second discharge port (13). That is, the second discharge port (13) can be provided to discharge air that has not been heat-exchanged. Since the heat exchanger (30) is arranged on the first flow path, the air discharged through the first discharge port (17) can be heat-exchanged air. Since the heat exchanger is not arranged on the second flow path, the air discharged through the second discharge port (13) can be air that has not been heat-exchanged.

[0130] Alternatively, the present invention may be configured to discharge heat-exchanged air through the second outlet (13). That is, a heat exchanger may also be positioned on the second flow path. Specifically, the heat exchanger for heat-exchanging air discharged through the second outlet (13) may be positioned in the receiving space (19) of the case (11). According to this configuration, the air conditioner (1) may provide heat-exchanged air through both the first outlet (17) and the second outlet (13).

[0131] A support stand (14) may be provided in the case (11). The support stand (14) may be placed at the bottom of the case (11). The support stand (14) may stably support the housing (10) against the floor.

[0132] A receiving space (19) in which electrical components (not shown) can be placed can be formed inside the case (11). Electrical components required for operating the air conditioner (1) can be placed in the receiving space (19). A second blower unit (26) can be placed in the receiving space (19).

[0133] The blower unit (20) may include a first blower unit (21) and a second blower unit (26). The second blower unit (26) may be arranged to be driven independently of the first blower unit (21). The rotation speed of the second blower unit (26) may be arranged to be different from the rotation speed of the first blower unit (21).

[0134] The first blower unit (21) may be disposed on the first flow path formed between the first suction port (12) and the first discharge port (17). Air may be introduced into the interior of the housing (10) through the first suction port (12) by the first blower unit (21). The air introduced through the first suction port (12) may move along the first flow path and be discharged to the exterior of the housing (10) through the first discharge port (17). The first blower unit (21) may include a first blower fan (22) and a first fan driving unit (23).

[0135] The first blower fan (22) may be an axial fan or a diagonal fan. However, the type of the first blower fan (22) is not limited thereto, and any configuration that allows air flowing in from the outside of the housing (10) to be discharged back to the outside of the housing (10) is sufficient. For example, the first blower fan (22) may be a cross fan, a turbo fan, or a sirocco fan.

[0136] In Fig. 10, three first blower fans (22) are provided, but the number of first blower fans (22) is not limited thereto and may be provided in various numbers as needed.

[0137] The first fan driving unit (23) can drive the first blower fan (22). The first fan driving unit (23) can be placed at the center of the first blower fan (22). The first fan driving unit (23) can include a motor.

[0138] The second blower unit (26) may be placed on the second flow path formed between the second suction port (15) and the second discharge port (13). Air may be introduced into the interior of the housing (10) through the second suction port (15) by the second blower unit (26). The air introduced through the second suction port (15) may move along the second flow path and be discharged to the exterior of the housing (10) through the second discharge port (13).

[0139] The second blower unit (26) may include a second blower fan (27), a second fan driving unit (28), and a fan case (29).

[0140] The second blower fan (27) may be a centrifugal fan. However, the type of the second blower fan (27) is not limited thereto, and the second blower fan (27) is sufficient as long as it has a configuration that allows air flowing in from the outside of the housing (10) to be discharged back to the outside of the housing (10). For example, the second blower fan (27) may be a cross fan, a turbo fan, or a sirocco fan.

[0141] In Fig. 10, two second blower fans (27) are provided, but the number of second blower fans (27) is not limited thereto and may be provided in various numbers as needed.

[0142] The second fan driving unit (28) can drive the second blower fan (27). The second fan driving unit (28) can be placed at the center of the second blower fan (27). The second fan driving unit (28) can include a motor.

[0143] The fan case (29) can cover the second blower fan (27). The fan case (29) can include a fan inlet through which air is drawn in and a fan outlet through which air is discharged. The positions of the fan inlet and the fan outlet can be determined in accordance with the type of the second blower fan (27).

[0144] In Fig. 10, the second blower unit (26) is illustrated as having a second blower fan (27) provided at each end of one second fan driving unit (28), but the configuration of the second blower unit (26) is not limited thereto, and the second fan driving unit (28) may be provided to drive each of the second blower fans (27).

[0145] A heat exchanger (30) may be disposed between the first blower unit (21) and the first discharge port (17). The heat exchanger (30) may be disposed on the first flow path. The heat exchanger (30) may absorb heat from air introduced through the first inlet port (12) or transfer heat to air introduced through the first inlet port (12). The heat exchanger (30) may include tubes and a header coupled to the tubes. However, the type of the heat exchanger (30) is not limited thereto.

[0146] The air conditioner (1) may include a panel (40) disposed on a portion of a front panel (16) in which a first discharge port (17) is formed. The panel (40) may have a plurality of holes that allow air discharged from the first discharge port (17) to be discharged more slowly than air discharged from the second discharge port. The plurality of holes may penetrate the inner and outer surfaces of the panel (40). The plurality of holes may be formed in a fine size. The plurality of holes may be uniformly distributed over the entire area of ​​the panel (40). The heat-exchanged air discharged through the first discharge port (17) by the plurality of holes may be uniformly discharged at a low speed.

[0147] The air conditioner (1) may include a first suction grill (51) that is coupled to a portion of the case (11) where the first suction port (12) is formed. The first suction grill (51) may be provided to prevent foreign substances from entering through the first suction port (12). To this end, the first suction grill (51) may include a plurality of slits or holes. The first suction grill (51) may be provided to cover the first suction port (12).

[0148] The air conditioner (1) may include a second suction grill (52) that is coupled to a portion of the case (11) where the second suction port (15) is formed. The second suction grill (52) may be provided to prevent foreign substances from entering through the second suction port (15). To this end, the second suction grill (52) may include a plurality of slits or holes. The second suction grill (52) may be provided to cover the second suction port (15).

[0149] An air conditioner (1) according to one embodiment of the present invention comprises a panel (40) including a housing (10), a heat exchanger (30) disposed inside the housing (10) to exchange heat with air introduced into the housing (10), and a plurality of holes formed to discharge the heat-exchanged air, wherein the plurality of holes have a diameter of 0.6 mm or more and 1 mm or less, preferably 0.7 mm or more and 0.9 mm or less, and the panel (40) may include a zinc-plated layer (3) on a surface of a zinc-plated steel sheet (2), a chromate film layer (4) on a surface of the zinc-plated layer (3), and a powder coating layer (5) on a surface of the chromate film layer (4). The present invention relates to an air conditioner (1) for its discharge performance, especially, in a windless air conditioner (1), if the diameter of the hole is less than 0.6 mm, air discharge cannot be performed smoothly, making it difficult for the air conditioner (1) to perform its function of controlling the air temperature, and if the diameter of the hole exceeds 1 mm, the speed of the air discharged from countless holes becomes slow, making it impossible to secure the desired cooling efficiency, and it is impossible to secure the uniform air distribution effect due to the Coanda effect. Therefore, by limiting the diameter of the hole of the air conditioner (1) as described above, noise is minimized during use of the air conditioner (1), ensuring a sense of stability during use, and controlling the wind volume so as not to directly expose the user to the wind, thereby preventing the user from being overly cold, while at the same time ensuring cooling efficiency.

[0150] Below, the present invention is described in detail through test examples.

[0151] <Test Example - Salt Spray Test>

[0152] The comparative example in Table 1 below is a steel sheet that was subjected to electrodeposition coating on a galvanized steel sheet that had been punched with a press device and then sprayed with an epoxy-polyester hybrid powder coating with a spray gun. In the case of the invention example, a galvanized steel sheet that had been punched with a press device was immersed in an acid solution containing, by weight %, 10% HCl, 45% H2SO, and the remainder water to perform deburring at 30°C for 5 minutes, and then the steel sheet was immersed in the cathode of a zinc alloy plating solution containing, by weight %, 94% zinc and 6% nickel, voltage was applied for 5 minutes, the steel sheet was immersed in a trivalent chromium solution for 5 minutes, primary drying was performed at 60°C, epoxy-polyester hybrid powder coating was sprayed with a spray gun, and secondary drying was performed at 200°C.

[0153] Table 1 below shows the results of observing whether rust occurred after 10 cycles of 8 hours of spraying and 16 hours of resting, with steel plates according to comparative examples and inventive examples each placed in a salt spray tester spraying a 5 wt% sodium chloride aqueous solution at 35°C, and 1 cycle of 8 hours of spraying and 16 hours of resting.

[0154] Comparative Example: No rust in salt spray test

[0155] As can be seen in Table 1 above, in the case of the comparative example, it was confirmed that rust of the type shown in Fig. 7 occurred near some holes after 10 cycles. However, in the case of the inventive example, it was confirmed through Table 1 and Fig. 8 that rust did not occur even after 13 cycles. A method for manufacturing a panel (40) according to an embodiment of the present invention may include a step (S1) of forming a plurality of holes in a steel plate by punching the steel plate, a step (S2) of deburring the steel plate, a step (S3) of plating the deburred steel plate, and a step (S4) of forming a film on the plated steel plate.

[0156] The method for manufacturing the above panel (40) may further include a step (S5) of first drying the steel plate on which the film is formed, a step (S6) of painting the first dried steel plate, and a step (S7) of second drying the painted steel plate.

[0157] The method for manufacturing the above panel (40) may include that the steel plate to be deburred includes a galvanized steel plate (2).

[0158] The method for manufacturing the above panel (40) may include the deburring step (S2) immersing the steel plate in an acidic solution in which at least one acid selected from the group consisting of HCl, HNO3, H2SO4 and HF is diluted in water.

[0159] The method for manufacturing the above panel (40) may be such that the acidic solution may include HCl and H2SO4, or a mixture thereof.

[0160] The manufacturing method of the above panel (40) may include the acid solution containing 10% or more and 20% or less of HCl and 5% or more and 10% or less of H2SO4 in weight %.

[0161] The method for manufacturing the above panel (40) may be such that the deburring step (S2) is performed at a temperature of 30°C or more and 40°C or less for 5 minutes or more and 10 minutes or less.

[0162] The manufacturing method of the above panel (40) may include a plating step (S3) in which the deburred steel plate is immersed in a zinc plating solution or a zinc alloy plating solution containing 91% or more and 97% or less of zinc and 3% or more and 9% or less of nickel by weight% and then electroplated.

[0163] The manufacturing method of the above panel (40) may be such that the plating layer formed in the plating step may have an average thickness of 15 µm or more and 20 µm or less.

[0164] The method for manufacturing the above panel (40) may include the film forming step (S4) of immersing the plated steel plate in a trivalent chromium solution.

[0165] The manufacturing method of the above panel (40) can be such that the first drying step (S5) dries the steel plate on which the film is formed at a temperature of 55°C or higher and 65°C or lower.

[0166] The manufacturing method of the above panel (40) can be such that the painting step (S6) can powder coat the first dried steel plate with epoxy-polyester hybrid powder coating.

[0167] The manufacturing method of the above panel (40) can dry the painted steel plate at a temperature of 180°C or higher and 200°C or lower in the second drying step (S7).

[0168] A panel (40) according to one embodiment is an air conditioner panel (40) including a plurality of holes for discharging air, and may include a galvanized steel sheet (2) having the plurality of holes, a galvanized layer (3) on a surface of the galvanized steel sheet (2), a chromate film layer (4) on the surface of the galvanized layer (3), and a powder coating layer (5) on the surface of the chromate film layer (4).

[0169] The panel (40) may include a zinc plating layer (3) containing zinc or a zinc content of 91% or more and 97% or less by weight and nickel of 3% or more and 9% or less, a chromate film layer (4) containing trivalent chromium, and a powder coating layer (5) containing an epoxy-polyester hybrid powder coating.

[0170] The above panel (40) may have an average thickness of the zinc plating layer (3) of 15 µm or more and 20 µm or less, an average thickness of the chromate film layer (4) of 0 µm or more and 1 µm or less, and an average thickness of the powder coating layer (5) of 50 µm or more and 80 µm or less.

[0171] An air conditioner (1) according to one embodiment comprises a housing (10), a heat exchanger (30) disposed inside the housing (10) to exchange heat with air introduced into the housing (10), and a panel (40) formed with a plurality of holes to discharge the heat-exchanged air, wherein the plurality of holes have a diameter of 0.6 mm or more and 1 mm or less, and the panel (40) may include a zinc-plated layer (3) on a surface of a zinc-plated steel plate (2), a chromate film layer (4) on a surface of the zinc-plated layer (3), and a powder coating layer (5) on a surface of the chromate film layer (4).

[0172] Above, the manufacturing method of the panel (40) according to one embodiment, the panel (40) and the air conditioner (1) including the same have been described.

[0173] The effects that can be obtained from the present disclosure are not limited to the effects mentioned above, and other effects that are not mentioned can be clearly understood by a person having ordinary skill in the art to which the present disclosure belongs from the description below.

[0174] Although the embodiments of the invention disclosed above have been illustrated and described, the disclosed invention is not limited to the specific embodiments described above, and various modifications may be implemented by a person having ordinary skill in the art to which the disclosed invention pertains without departing from the gist claimed in the claims.

Claims

1. A step (S1) of forming a plurality of holes in a steel plate by punching the steel plate; Step (S2) of deburring the above steel plate; Step (S3) of plating the above deburred steel plate and A method for manufacturing a panel, comprising: a step (S4) of forming a film on the plated steel plate.

2. In claim 1, Step (S5) of first drying the steel plate on which the above film is formed; Step (S6) of painting the first dried steel plate; and A method for manufacturing a panel further comprising a step (S7) of secondary drying of the painted steel plate.

3. In claim 1, The above deburring steel sheet is a method for manufacturing a panel including a galvanized steel sheet.

4. In claim 1, The above deburring step (S2) is performed by treating the steel sheet with HCl, HNO 3 , H 2 SO 4 A method for manufacturing a panel comprising immersing at least one acid selected from the group consisting of and HF in an acid solution diluted in water.

5. In claim 4, The above acidic solution is HCl and H 2 SO 4 , or a method for manufacturing a panel comprising a mixture thereof.

6. In claim 5, The above acidic solution contains 10% or more and 20% or less of HCl and H by weight. 2 SO 4 A method for manufacturing a panel containing 5% or more and 10% or less.

7. In claim 4, A method for manufacturing a panel, wherein the above deburring step (S2) is performed at a temperature of 30°C or higher and 40°C or lower for 5 minutes or longer and 10 minutes or shorter.

8. In claim 1, The above plating step (S3) is a method for manufacturing a panel including electroplating by immersing the de-burred steel plate in a zinc plating solution or a zinc alloy plating solution containing 91% or more of zinc and 97% or less of nickel in weight %.

9. In claim 1, A method for manufacturing a panel, wherein the plating layer formed in the above plating step has an average thickness of 15 ㎛ or more and 20 ㎛ or less.

10. In claim 1, The above film forming step (S4) is a method for manufacturing a panel including immersing the plated steel plate in a trivalent chromium solution.

11. In claim 2, The above first drying step (S5) is a method for manufacturing a panel in which the steel plate on which the film is formed is dried at a temperature of 55°C or higher and 65°C or lower.

12. In claim 2, The above-mentioned painting step (S6) is a method for manufacturing a panel by powder-coating an epoxy-polyester hybrid powder coating (Epoxy-Polyester Hybrid Powdercoating) on ​​the first dried steel plate.

13. In claim 2, The above secondary drying step (S7) is a method for manufacturing a panel in which the painted steel plate is dried at a temperature of 180°C or higher and 200°C or lower.

14. In a panel for an air conditioner including a plurality of holes for discharging air, Galvanized steel sheet having the above-mentioned plurality of holes; A zinc-plated layer on the surface of the above zinc-plated steel sheet; A chromate film layer on the surface of the zinc plating layer; and A panel comprising a powder coating layer on the surface of the above chromate film layer.

15. Housing; A heat exchanger positioned inside the housing to exchange heat with air flowing into the housing; and A panel including a plurality of holes formed to discharge the heat-exchanged air, wherein the plurality of holes include a panel having a diameter of 0.6 mm or more and 1 mm or less, The above panel is a zinc-plated layer on the surface of a zinc-plated steel sheet, A chromate film layer on the surface of the zinc plating layer and An air conditioner comprising a powder coating layer on the surface of the chromate film layer.

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