Home Appliance Exterior Panel Edge Deposition Removal
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Solution Overview
Problem
Conventional exterior panels for home appliances face issues with discoloration and peeling of metal deposition layers due to moisture and foreign materials, as well as weak bonding strength between the metal and film layers, leading to separation and a lack of aesthetic unity.
Innovation Solution
The solution involves forming a base layer with a metal deposition layer in the center and a printing layer at the edges, where the deposition layer is removed to prevent exposure and peeling, and directly bonding the metal layer to the film using an adhesive layer, while the printing layer matches the color and texture of the deposition layer for a unified appearance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Illumination intensity
If a metal deposition layer is formed on the entire surface including edges, then aesthetic effect and luminance are improved, but the deposition layer becomes exposed to moisture and foreign materials causing discoloration and peeling
Solution Approach 1:
The patent divides the base layer surface into two zones: a central area where metal deposition is applied for aesthetic effect, and an edge area where deposition is omitted to prevent exposure to moisture and foreign materials. This spatial segmentation resolves the contradiction by localizing the deposition function to where it provides benefit without causing harm.
Solution Approach 2:
The patent applies different treatments to different regions of the base layer: the central region receives metal deposition for luminance and aesthetic quality, while the edge region remains untreated or receives protective coating only to ensure reliability and prevent discoloration. This local differentiation allows each zone to optimize its specific function.
2Ease of manufacture
If a deposition layer is used to bond the film layer to the metal layer, then the bonding process is simplified, but the bonding strength is weak and peeling occurs easily
Solution Approach 1:
The patent removes the metal deposition layer from the edge portions of the base layer, exposing the underlying metal surface. This extraction allows for direct bonding between the film layer and the metal base layer at the edges, eliminating the weak deposition layer interface and creating stronger bonds that resist peeling.
3Strength
If the deposition layer is removed at boundary portions, then direct bonding between metal layer and film is achieved improving bonding strength, but a lack of material unity and aesthetic continuity occurs
Solution Approach 1:
The patent applies a printing layer to the edge portions of the base layer that replicates the visual appearance of the metal deposition layer. This copying of the aesthetic characteristics allows the edge area to match the central area's appearance, maintaining material unity and aesthetic continuity even though the actual metal deposition is removed for bonding purposes.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
This approach prevents discoloration and peeling of the metal deposition layer, maintains the lamination state of the film and metal layer, and achieves a sense of material unity by matching the color and texture of the removed deposition layer, enhancing the aesthetic and durability of the exterior panel.
Implementation Method 1
a metal layer and a coating layer are formed on an upper surface of a base layer
Implementation Method 2
directly bonding the metal layer to the film using an adhesive layer
Data Source
AI summary
The present disclosure relates to an exterior panel for a home appliance and a method of manufacturing the same.The exterior panel for a home appliance according to one aspect includes: a base layer made of a metal material, a deposition layer formed at a center except for an edge of an upper layer of the base layer and made of a metal material, and a coating layer formed on the deposition layer and an upper surface of the edge of the base layer, on which the deposition layer is not formed.