Refrigerator Outer Plate Punching Method for Uniform Through Holes
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Conventional methods for manufacturing refrigerator door outer plates face challenges such as non-uniform through hole sizes, high costs, and deformation issues during the etching or laser processing of fine holes, leading to uneven appearances and increased manufacturing time.
Innovation Solution
A method involving a steel plate with a protective film, punched through a die to form uniform through holes, followed by horizontal movement to form additional holes, with a diffusion sheet on the rear to shield holes and a hole-filling material applied to ensure light transmission and prevent burrs, simplifying the process and reducing costs.
Engineering Contradictions & Design Principles
Engineering 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
Solution Approach 1:
The patent replaces the chemical etching process with a mechanical punching process. The punch physically penetrates the outer plate to form through holes, eliminating the chemical reactions and non-uniformities associated with etching. This mechanical approach ensures uniform hole sizes and clean edges without the complexity of chemical control.
2Productivity
If laser processing is used to form through holes, then the through holes can be formed quickly, but the coating layer around the through hole is damaged by thermal deformation
Solution Approach 1:
The patent replaces laser processing with mechanical punching. Instead of using thermal energy that causes localized heating and coating damage, a mechanical punch directly forms the through holes. This eliminates thermal deformation entirely while maintaining high production speed through efficient mechanical forming.
3Productivity
If laser processing is used to form through holes, then the through holes can be formed quickly, but additional post-processing is required to remove burrs
Solution Approach 1:
The patent uses a mechanically optimized punching process that forms clean through holes without excessive burrs. The punch design and forcing conditions are controlled to minimize material deformation and burr formation, eliminating or reducing the need for post-processing operations.
4Manufacturing precision
If etching or laser processing is used, then through holes can be formed, but the manufacturing cost is remarkably high
Solution Approach 1:
The patent replaces expensive chemical etching and laser processing equipment with simpler, more cost-effective mechanical punching equipment. The mechanical process uses conventional press machinery rather than specialized chemical or laser systems, significantly reducing capital investment and operational costs while maintaining high precision.
5Productivity
If through holes are formed by punching, then the process is simplified and productivity is improved, but burrs may be generated around the through holes
Solution Approach 1:
The patent optimizes punching parameters including forcing conditions, punch geometry, and material clamping to minimize burr formation. By carefully controlling these parameters, the mechanical punching process achieves clean hole edges suitable for display applications without requiring additional deburring operations.
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 enables the formation of uniform, deformation-free through holes with improved appearance and reduced manufacturing time and cost, enhancing productivity and preventing burrs and coating damage.
Implementation Method 1
forming one of a plurality of through holes by a vertical movement of a punch
Implementation Method 2
attaching a diffusion sheet on the rear surface of the steel plate to shield one or more of the plurality of through holes
Data Source
Figure 1
Figure 2
Figure 3
AI summary
A method for manufacturing an outer plate for a refrigerator includes providing a steel plate with a first protective film attached to a front 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 outer 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. Each of the plurality of through holes are formed by sequentially penetrating the first protective film and the steel plate with the punch, wherein the horizontal moving of the steel plate and the forming of one of the plurality of through holes by the vertical movement of the punch are repeatedly performed while the steel plate is seated on the die at other ones of the plurality of set positions.