Refrigerator Out Plate Punching Method for Uniform Through Holes

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Solution Overview

Problem

Conventional methods for manufacturing out plates for refrigerators face challenges such as non-uniform through hole sizes, high costs, and inefficiencies in the etching and laser processing methods, which result in uneven appearances and increased manufacturing time.

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 and appearance quality.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Manufacturing precision

If etching is used to form through holes, then fine holes can be formed, but the size of through holes is not uniform and the appearance is uneven

Engineering Contradiction:

Improvethrough hole size uniformityVSAvoidmanufacturing process complexity

Core Design Contradiction:

Manufacturing precisionVSEase of manufacture

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 chemical reactions and uniformity issues associated with etching. This mechanical approach ensures consistent hole sizes and uniform appearance while simplifying the manufacturing process.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

2Manufacturing precision

If laser processing is used to form through holes, then through holes can be formed, but the coating layer around the through hole is damaged by thermal deformation

Engineering Contradiction:

Improvethrough hole formationVSAvoidthermal deformation damage

Core Design Contradiction:

Manufacturing precisionVSObject-affected harmful factors

Solution Approach 1:

The patent replaces laser processing with mechanical punching. Instead of using thermal energy that causes localized heating and deformation, the punch directly mechanically removes material to form through holes. This eliminates thermal deformation and protects the coating layer surrounding the holes from heat-induced damage.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

3Manufacturing precision

If laser processing is used to form through holes, then through holes can be formed, but additional post-processing is required to remove burrs

Engineering Contradiction:

Improvethrough hole formationVSAvoidpost-processing requirements

Core Design Contradiction:

Manufacturing precisionVSDevice complexity

Solution Approach 1:

The patent uses a punching process with a specially designed punch that creates clean cuts through the steel plate. The mechanical punching action, when properly controlled, produces through holes with minimal burr formation, eliminating or reducing the need for additional post-processing steps to remove burrs.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

4Manufacturing precision

If laser processing is used to form through holes, then through holes can be formed, but manufacturing cost is remarkably high

Engineering Contradiction:

Improvethrough hole formationVSAvoidmanufacturing cost

Core Design Contradiction:

Manufacturing precisionVSEase of manufacture

Solution Approach 1:

The patent replaces expensive laser processing equipment and operations with a more cost-effective mechanical punching system. The punching process uses simpler machinery, consumes less energy, and has lower operational costs while achieving the same through hole formation goal, thereby significantly reducing manufacturing costs.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

5Manufacturing precision

If conventional methods are used to form through holes, then through holes can be formed, but the manufacturing process is complex and productivity is low

Engineering Contradiction:

Improvethrough hole formationVSAvoidmanufacturing efficiency

Core Design Contradiction:

Manufacturing precisionVSProductivity

Solution Approach 1:

The patent replaces complex multi-step processes (etching, laser processing with post-processing) with a single-step mechanical punching operation. This consolidation of steps into one efficient process dramatically improves manufacturing throughput and productivity while maintaining precise through hole formation.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Data Source

PatentUS11890662B2Method for manufacturing out plate for refrigerator

Publication Date: 2024.02.06 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.