Method of manufacturing outer case for hot water unit
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Solution Overview
Problem
The existing manufacturing methods for hot water unit outer cases face challenges such as poor workability, high manufacturing costs, and difficulty in applying paint to complex patterns and uneven surfaces, particularly due to the inefficiencies of spray painting and transfer coating methods, which result in paint wastage and susceptibility to environmental damage.
Innovation Solution
A method involving inkjet printing followed by pressing and clear coating, where inkjet printing is used to apply designs and patterns on a metal plate before pressing, and a clear layer containing ultraviolet absorbers is applied post-pressing to enhance durability and protection, utilizing ultraviolet curable or thermosetting resins for improved results.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Quantity of substance
If spray painting is used to paint the outer case, then the surface can be covered with color, but masking and color matching become troublesome and paint is wasted
Solution Approach 1:
The patent replaces the mechanical spray painting system with a digital printing system that uses print heads to deposit paint directly onto the outer case surface. This substitution eliminates the need for masking and manual spraying operations, thereby improving workability while maintaining paint coverage capability.
Solution Approach 2:
The patent changes the painting method from spray-based to print-based, fundamentally altering how paint is applied. The digital printing system allows for precise control of paint deposition parameters, enabling complex patterns and multiple colors without the waste and complexity associated with spray painting and masking.
2Quantity of substance
If spray painting is used, then color can be applied, but skillful operation is required and productivity is poor
Solution Approach 1:
The patent replaces manual spray painting operations with an automated digital printing system. The print heads are controlled by a computer to automatically deposit paint according to predetermined patterns, eliminating the need for skilled operators and significantly improving manufacturing efficiency and productivity.
Solution Approach 2:
The digital printing system is self-controlled through computer programming, where the print heads automatically move and deposit paint without human intervention during the painting process. This automation eliminates dependency on skilled workers and maintains consistent quality while improving productivity.
3Shape
If press molding is performed before painting, then the outer case shape is formed, but it is difficult to properly apply paint to uneven portions
Solution Approach 1:
The patent performs the painting operation before the press molding process. By applying the paint pattern to the flat metal plate prior to forming the three-dimensional outer case shape, the system ensures that paint is applied to a flat, accessible surface where digital printing can operate effectively, avoiding the difficulty of painting uneven portions after molding.
Solution Approach 2:
The patent inverts the conventional sequence of operations by painting before molding instead of after. This reversal allows the digital printing system to apply paint to a flat surface where it can access all areas evenly, and the subsequent molding process then forms the three-dimensional shape with the paint already in place, solving the problem of painting uneven portions.
4Quantity of substance
If transfer type coating is used, then coating can be applied, but a transfer plate is required which leads to high cost
Solution Approach 1:
The patent replaces the transfer plate-based coating system with a digital printing system using print heads. This substitution eliminates the need for expensive transfer plates while maintaining the ability to apply coatings with complex patterns and multiple colors, thereby reducing device complexity and manufacturing cost.
5Quantity of substance
If conventional painting methods are used, then the outer case can be painted, but the paint is easily damaged by wind, rain, sunlight and contamination
Solution Approach 1:
The patent applies a multi-layer coating structure consisting of a base paint layer and a protective clear coat layer. The clear coat layer contains ultraviolet absorbers and other protective additives that provide resistance against wind, rain, sunlight, and contamination, thereby enhancing the reliability and weather resistance of the painted outer case while maintaining the decorative paint layer underneath.
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 method improves workability and productivity by eliminating the need for masking and skillful spraying, reduces paint wastage, and enhances the durability and weather resistance of the outer case designs, allowing for more complex and detailed patterns while maintaining cost-effectiveness.
Implementation Method 1
an inkjet printing step of forming an inkjet printing layer by performing inkjet printing on the flat metal plate
Implementation Method 2
a clear coating step of forming a clear layer on the inkjet printing layer... The clear coating is, for example, a spray coating which uses a clear paint containing an ultraviolet curable resin or a thermosetting resin
Implementation Method 3
a clear coating step of forming a clear layer on the inkjet printing layer... which uses a clear paint containing an ultraviolet curable resin
Implementation Method 4
a clear coating step of forming a clear layer on the inkjet printing layer... which uses a clear paint containing an ultraviolet curable resin or a thermosetting resin
Implementation Method 5
a pressing step of pressing a flat metal plate to form a component part of an outer case
Data Source
AI summary
This method of manufacturing an outer case for a hot water unit involves a pressing step for subjecting a flat metal plate (30a) to press processing to form a component part (3) of the outer case (C), and a painting step for painting text, symbols, figures or patterns on the component part (3), wherein the painting step involves an inkjet printing step for forming an inkjet printing layer (4) by performing inkjet printing on the flat metal plate (30a). The pressing step is performed after the inkjet printing step, and after the pressing step, there is further a clear coating step for forming a clear layer (5) on the inkjet printing layer (4).