Method for manufacturing out plate for refrigerator

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Solution Overview

Problem

Conventional methods for manufacturing out plates for refrigerators face challenges such as non-uniform hole sizes, high costs, and inefficiencies in forming fine through holes, which affect the appearance and functionality of the display part, and require costly and time-consuming processes like etching or laser processing.

Innovation Solution

A method involving a steel plate with a protective film, seated on a die, where through holes are formed using a punch for uniformity and efficiency, with horizontal movement to prevent burrs and deformation, and a hole-filling material is used to ensure light transmission without additional masking steps.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Manufacturing precision

If etching is used to form fine through holes, then the through holes can be formed in a fine size, but the size of the through holes is not uniform and the appearance is uneven, and the process is costly and time-consuming

Engineering Contradiction:

Improvethrough hole size uniformityVSAvoidmanufacturing time and cost

Core Design Contradiction:

Manufacturing precisionVSProductivity

Solution Approach 1:

The patent replaces the chemical etching process with a mechanical punching process. The punch physically penetrates the steel plate to form through holes, eliminating the need for chemical etchants and post-processing. This mechanical approach ensures uniform hole sizes while significantly reducing manufacturing time and cost.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Solution Approach 2:

The patent changes the processing parameters from chemical etching conditions to mechanical punching conditions. By controlling the punch geometry, material properties, and punching speed, the process achieves fine through holes with uniform sizes without the variability inherent in etching processes.

Inventive Principle:

Principle #35Parameter changes

2Ease of manufacture

If laser processing is used to form through holes, then the through holes can be formed, but the coating layer around the through hole is damaged by thermal deformation, and additional post-processing is required to remove burrs, and manufacturing cost is remarkably high

Engineering Contradiction:

Improvethrough hole formation capabilityVSAvoidcoating layer damage and burrs

Core Design Contradiction:

Ease of manufactureVSObject-affected harmful factors

Solution Approach 1:

The patent replaces laser processing with mechanical punching. This substitution eliminates thermal deformation that damages the coating layer and prevents burr formation. The mechanical punch cleanly penetrates the steel plate without generating the thermal effects that cause harmful deformations.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Solution Approach 2:

The patent converts the potential harm of mechanical punching (which could cause burrs) into a benefit by optimizing the punching process. The controlled mechanical action produces clean edges without burrs, transforming what could be a harmful effect into a clean, precise cutting method.

Inventive Principle:

Principle #22Blessing in disguise (Convert harm into benefit)

3Productivity

If conventional methods are used to form through holes, then the process can be completed, but the appearance of the display part is degraded and identification performance is reduced

Engineering Contradiction:

Improvethrough hole formation efficiencyVSAvoiddisplay part appearance quality

Core Design Contradiction:

ProductivityVSManufacturing precision

Solution Approach 1:

The patent replaces conventional etching and laser methods with mechanical punching. This substitution produces uniform, clean through holes that maintain the aesthetic appearance of the display part while improving manufacturing efficiency. The punched holes have consistent sizes and smooth edges, enhancing both appearance and light transmission for better identification performance.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Data Source

PatentUS20240116097A1Method for manufacturing out plate for refrigerator

Publication Date: 2024.04.11 LG ELECTRONICS INC

AI summary

A method for manufacturing an out plate for a refrigerator includes providing a steel plate with a protective film attached to a surface thereof; seating the steel plate on a die and forming one of the plurality of through holes by a vertical movement of a punch; and horizontally moving the steel plate to one of a plurality of set positions to form another one of the plurality of through holes in the steel plate by the vertical movement of the punch, wherein the out plate defines a front surface of a door of the refrigerator and includes a display part, wherein a plurality of through holes are formed therein, and a display assembly comprising a plurality of light emitting diodes (LEDs) that are configured to transmit light through the plurality of through holes configured to display information.