Metal Panel Edge Forming to Eliminate Tearing and Sharp Borders
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Solution Overview
Problem
Conventional oven range door frames manufactured using metal materials face issues with edge tearing and low impact strength due to thin thickness, leading to increased welding costs and reduced productivity, as well as safety concerns from sharp edges.
Innovation Solution
A manufacturing method involving cutting a metal plate to form a cutaway portion, bending the border, and coupling a bracket to the cutaway groove, which eliminates sharp edges and simplifies the manufacturing process by reducing the need for welding and polishing.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Quantity of substance
If the edge portion is formed using a metal material for general processing (e.g., stainless steel) with thin thickness (≤0.8 mm), then the material usage is efficient and cost-effective, but the edge portion is torn and impact strength is low
Solution Approach 1:
The invention combines metal material with a resin layer to form a composite panel. The resin layer is applied to the metal plate and cured to create a composite structure that maintains the metal's strength while eliminating sharp edges and improving impact resistance. This composite approach allows the use of thin metal plates without compromising edge strength.
Solution Approach 2:
The invention changes the physical and chemical parameters of the metal plate surface by applying a resin coating. The resin layer modifies the surface characteristics, filling in sharp edges and creating a rounded, safe surface while maintaining the underlying metal structure's strength properties.
2Strength
If the upper, lower and side surfaces are separated by cutting and bending to prevent edge tearing, then the edge strength is improved, but the manufacturing process complexity increases due to welding and polishing requirements
Solution Approach 1:
The invention extracts the problematic sharp edge portion by applying a resin layer that covers and rounds the edges. This eliminates the need for complex welding and polishing processes to remove sharp edges, as the resin layer itself provides the rounded, safe surface finish.
Solution Approach 2:
The resin layer acts as a cost-effective, easily applied coating that replaces expensive and time-consuming welding and polishing operations. The resin can be applied through simple coating processes and cured to provide the desired edge finish without requiring skilled welding or polishing operations.
3Shape
If welding and polishing processes are performed on the separated surfaces to form the door frame, then the external appearance is improved, but the productivity is reduced and manufacturing cost increases
Solution Approach 1:
The resin coating provides a simple, fast, and cost-effective method to achieve the desired external appearance. Instead of time-consuming welding and polishing operations, the resin can be applied through coating processes and cured relatively quickly, significantly improving manufacturing productivity while maintaining or enhancing appearance quality.
Solution Approach 2:
The resin layer changes the surface parameters of the metal plate, providing a smooth, rounded finish that improves external appearance. This parameter change occurs through the coating and curing process rather than through multiple mechanical operations like welding and polishing, thereby increasing productivity.
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 enhances the impact strength of the metal panel, reduces manufacturing costs, and improves safety by eliminating sharp edges, while simplifying the manufacturing process.
Implementation Method 1
cutting a metal plate to form a cutaway portion at a specified area of a border; bending the border on opposite sides of the cutaway portion
Implementation Method 2
coupling a bracket to a cutaway groove formed at the border by the bending
Data Source
AI summary
A metal panel, a manufacturing method thereof and a cooking device using the metal panel capable of improving an external appearance of edges, enhancing efficiency of a manufacturing process and reducing the manufacturing cost. The manufacturing method of a metal panel includes cutting a metal plate to form a cutaway portion at a specified area of a border, bending the border on opposite sides of the cutaway portion, and coupling a bracket to a cutaway groove formed at the border by the bending.