Panel Surface Processing Rollers for Uniform Hairline Finishes
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Solution Overview
Problem
Existing methods for surface-processing metal panels used in home appliances often result in non-uniform scratch patterns and hair-line textures, leading to a mottled appearance and potential chattering marks, which can detract from the luxurious look intended by these processes.
Innovation Solution
An apparatus comprising a contacting roller, a pressing roller, and supporting rollers, along with pinching apparatuses, is used to uniformly process the surface of metal panels, ensuring consistent density and thickness of patterns and textures by applying and releasing pressure in a controlled manner.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If conventional surface-processing methods are used on metal panels, then scratch patterns and hair-line textures can be formed, but the patterns and textures are non-uniform in density and thickness, resulting in a mottled appearance
Solution Approach 1:
The patent applies parameter changes by controlling the pressure, speed, and temperature parameters during the surface-processing operation. The pressing roller applies controlled pressure to ensure uniform contact between the contacting roller and panel, while the heating unit maintains optimal temperature for consistent pattern formation. These parameter controls directly address the non-uniformity issue in scratch patterns and hair-line textures.
Solution Approach 2:
The patent introduces intermediary elements including a pressing roller that mediates the pressure application between the contacting roller and panel, and a heating unit that mediates temperature control during processing. These intermediaries ensure uniform transmission of energy and force across the panel surface, preventing mottled appearance and achieving consistent pattern density and thickness.
2Illumination intensity
If surface-processing is performed to create luxurious appearance, then scratch patterns and hair-line textures are formed, but chattering marks appear on the panel surface
Solution Approach 1:
The patent applies beforehand cushioning by using a heating unit to pre-heat the panel before surface-processing. This thermal preparation softens the metal surface, making it more receptive to the scratching process and reducing the formation of chattering marks. The pressing roller also provides cushioning pressure to ensure smooth contact during processing, preventing harmful vibrations and marks on the panel surface.
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
The solution ensures that scratch patterns and hair-line textures are formed uniformly across the panel, preventing mottling and undesired patterns, thereby enhancing the aesthetic quality of home appliance surfaces.
Implementation Method 1
a contacting roller configured to perform surface-processing on a panel that is to be processed; a pressing roller configured to press the panel toward the contacting roller
Data Source
AI summary
Disclosed herein are an apparatus of manufacturing a panel for home appliance by performing uniform surface processing on the panel and a method of manufacturing a home appliance by performing uniform surface processing on a panel. The apparatus of manufacturing a panel for home appliance includes a contacting roller configured to perform surface-processing on a panel that is to be processed; a pressing roller configured to press the panel toward the contacting roller; and a supporting roller configured to support a center middle portion of the contacting roller.