JP2016054833A - Washing machine and manufacturing method of washing machine - Google Patents

Abstract

PROBLEM TO BE SOLVED: To provide a washing machine in which an antifouling function is applied at a portion where the function is utilized most effectively.SOLUTION: A washing machine of the embodiment is the washing machine in which a side part of a rotary tub which is provided in a water tub rotatably is formed by caulking and joining both end parts of a metal plate material. Antifouling coating having an antifouling function is applied at least at a portion which is joined by caulking out of an outer surface of the side part of the rotary tub.SELECTED DRAWING: Figure 1

Description

  Embodiments described herein relate generally to a washing machine and a method for manufacturing the washing machine.

  Conventionally, it has been considered to provide various functional films on a water tank of a washing machine. For example, Patent Document 1 discloses a technique in which a heat insulating paint film is provided on the inner surface of a water tank in order to reduce power consumption during drying. Further, in this Patent Document 1, by including hydrophilic hollow beads in the water-repellent heat-insulating coating film, the water film adhering to the surface of the film is spread and evaporated. It is disclosed to further reduce power consumption.

  By the way, in recent years, paints that exhibit antifouling functions due to, for example, hydrophilicity and water repellency have been developed, and if such paints are applied to the inner surface of a water tank of a washing machine, the inner surface of the water tank is improved by the antifouling function. It can be kept clean. However, the water stored in the water tank is contacted with the inner surface of the water tank during the washing operation or the rinsing operation, and the water splashed from the internal rotating tank is also in contact with the water during the dehydration operation. Therefore, the inner surface of the water tank can be kept relatively clean without applying such antifouling function paint, and therefore even if the antifouling function is held on the inner surface of the water tank, the function is effective. It cannot be used.

JP 2010-172436 A

  The present embodiment provides a washing machine applied to a part where the antifouling function can be most effectively utilized, and a washing machine manufacturing method for manufacturing the washing machine.

  The washing machine of the present embodiment is a washing machine in which a side portion of a rotating tub that is rotatably provided in a water tub is formed by caulking and joining both end portions of a metal plate material, the rotating tub side An antifouling coating having an antifouling function is applied to at least a portion joined by caulking of the outer surface of the portion.

  The manufacturing method of the washing machine according to the present embodiment is a method of manufacturing a washing machine in which side portions of a rotating tub provided rotatably in the water tub are formed by caulking and joining both end portions of a metal plate. In order to form an antifouling coating having an antifouling function on at least a portion joined by caulking of the outer surface of the side portion of the rotating tank before or after the joining step of caulking and joining the both ends of the plate material The coating process is performed.

Vertical side view schematically showing a configuration example of a vertical washing machine according to the present embodiment Longitudinal sectional view schematically showing a configuration example of a drum type washing machine according to the present embodiment The figure which shows an example of a press work process roughly The figure which shows an example of a hole formation process and a protrusion formation process roughly The figure which shows roughly an example of the junction part and shaping | molding process part which are set to a board | plate material The figure which shows an example of a bending process roughly The perspective view which shows roughly an example of the intermediate body of the rotary tank obtained by a joining process Cross-sectional view schematically showing the caulking portion Longitudinal sectional view schematically showing the caulking portion Diagram showing an example of drawing process The figure which shows an example of the attachment process of a bottom member roughly The figure which shows an example of the attachment process of a balance ring roughly The figure which shows an example of a diameter expansion process roughly The figure which shows an example of the attachment process of a backplate roughly The figure which shows an example of a coating process roughly

  Hereinafter, an embodiment according to a washing machine and a method for manufacturing the washing machine will be described with reference to the drawings. For example, the washing machine 100 shown in FIG. 1 is a so-called vertical type washing machine in which the rotation center axis of the rotating tub extends in the vertical direction, and the bottom of the outer box 101 constituting the outer shell has an open top surface. A cylindrical water tank 102 is elastically supported by an elastic suspension mechanism 103. Inside the water tank 102, a bottomed cylindrical rotating tank 104 having an open upper surface is rotatably provided.

  The rotating tank 104 has a body portion made of a metal body member 104a made of, for example, stainless steel, and a bottom portion made of, for example, a synthetic resin bottom member 104b. A reinforcing member 104c for reinforcing the bottom member 104b, in other words, the bottom of the rotating tub 104, is provided outside the bottom member 104b constituting the bottom of the rotating tub 104. The reinforcing member 104c is made of metal such as a stainless plate. The rotating tub 104 is configured to rotate about a vertical axis, and is a washing tub for washing laundry, a washing tub for rinsing the laundry, and a dehydration tub for a dehydration step for dehydrating the laundry. Also used as.

  The rotary tank 104 has a large number of holes 105a in its peripheral wall. These holes 105a penetrate the peripheral wall portion of the rotating tub 104 and allow water and air to pass therethrough. In the drawing, only a part of these holes 105 is shown. The rotating tank 104 has a large number of protrusions 105b on its peripheral wall. In this case, the protrusion 105 b protrudes inward of the rotary tank 104. A synthetic resin balance ring 106 in which a liquid such as salt water is sealed is attached to the upper part of the rotating tank 104. The balance ring 106 is fixed from the outer surface side of the rotating tub 104 by a metal screw 106a made of, for example, stainless steel. A synthetic resin stirring body 107 is rotatably provided at the bottom of the rotary tank 104.

  A drainage path 108 is provided in the lower part of the water tank 102. The drainage passage 108 is provided with a drainage valve 109. By opening the drainage valve 109, the water in the water tank 102 is discharged outside the apparatus. An air trap 110 for detecting the water level is provided at the bottom of the water tank 102. A water level sensor (not shown) is connected to the air trap 110 via an air tube 111. In this case, the water level sensor includes a pressure sensor, and detects the water level in the water tank 102 based on the pressure in the air trap 110.

  A drive mechanism 113 is provided at the center of the lower part of the water tank 102. The drive mechanism unit 113 includes a motor capable of variable speed drive, a clutch mechanism, a speed reducer, a brake device, and the like. Further, the drive mechanism 113 includes a dehydrating shaft 113 a for mainly transmitting the rotational force of the motor to the rotating tub 104 and a washing shaft 113 b for mainly transmitting the rotational force of the motor to the stirring body 107. The dehydrating shaft 113a is an example of a rotating tank rotating shaft, and the washing shaft 113b is an example of an agitator rotating shaft. During the washing process or the rinsing process, the drive mechanism 113 transmits the rotational force of the motor to the agitator 107 via the washing shaft 113b by decelerating by the speed reducer and switching the clutch mechanism. During the dehydration stroke, the driving mechanism 113 transmits the rotational force of the motor to the rotating tank 104 and the stirring body 107 at high speed via the dehydrating shaft 113a by switching the clutch mechanism without decelerating by the reduction gear. .

  A top cover 114 is provided on the top of the outer box 101. The top cover 114 is provided with an openable / closable lid 115, for example, which opens and closes the laundry entrance. A tank cover 102 a is attached to the upper part of the water tank 102. An operation panel 117 is provided at the front portion of the top cover 114. A control device (not shown) for controlling the overall operation of the washing machine 100 is provided on the back side of the operation panel 117. A water supply mechanism (not shown) that supplies water from the water tap into the water tank 102 is provided at the rear portion of the top cover 114.

  In addition, a circular concave region in which the stirring body 107 is disposed is provided on the inner bottom portion of the rotating tank 104. In addition, a pump chamber 118 is formed between the concave region and the stirring body 107. Here, the stirring body 107 has a disc shape having a protrusion on the upper surface for generating a rotating water flow. Moreover, the stirring body 107 has a plurality of water passage holes that vertically penetrate the plate surface. In addition, a plurality of pump blades 107 a are integrally provided on the lower surface of the stirring body 107. The pump blade 107a has a thin plate shape that extends radially from the central portion substantially in the radial direction. A plurality of outlets for allowing water to flow out from the pump chamber 118 are provided on the outer peripheral portion of the pump chamber 118. In this case, on the outer peripheral portion of the pump chamber 118, for example, three outlets are provided at three positions that are 120 degrees apart.

  A plurality of water passages 119 are provided on the side wall of the rotary tank 104 so as to extend upward from the respective outlets. The water flow portion 119 is for pumping water flowing out from the pump chamber 118. In this case, although only one is shown in FIG. 1, three water passages 119 are provided corresponding to the three outlets. These water passages 119 have a water spout 119a in the upper part thereof. When the stirring body 107 rotates in the pump chamber 118, the water in the rotating tank 104 is discharged from the outlet of the pump chamber 118 toward the outer peripheral direction. Further, the water rises in the water passage 119 and is sprinkled into the rotary tank 104 from the water spout 119a. Thereby, water comes to be supplied into the rotary tank 104 from the water spout 119a in a shower shape.

  And the water flow path 119 shown in FIG. 1 is provided in the position which opposes the junction part of the rotating tank 104 mentioned later in detail. A disinfectant unit 120 is detachably attached to a lower portion of the water passage 119 provided to face the joint. This disinfectant unit 120 includes an unillustrated disinfectant inside a disinfectant case made of, for example, a resin material. The disinfectant case is provided with a large number of holes (not shown), and a part of the water flowing in the water passage 119 flows into the disinfectant case. Thereby, the disinfectant dissolves in the water flowing into the disinfectant case, and the water containing the disinfecting component flows through the water passage 119 and is sprinkled from the water spout 119a.

  Further, for example, the washing machine 200 shown in FIG. 2 is a so-called horizontal shaft type drum type washing machine in which the rotation center axis of the rotating tub is horizontal or slightly inclined, and the outer box 201 constituting the outer shell is made of synthetic resin. It comprises a base 202 made of metal and a box body 203 coupled to the base 202. In FIG. 2, a laundry entrance / exit 204 is provided at a substantially central portion of the front surface of the box body 203 on the left side. A door 205 for opening and closing the laundry entrance / exit 204 is provided on the front surface of the box body 203. An operation panel 206 is provided on the upper portion of the front surface of the box body 203. On the back side of the operation panel 206, a control device 207 for controlling the overall operation of the washing machine 200 is provided. In the outer box 201, a bottomed cylindrical water tank 208 is provided with the back side, which is the bottom, closed. The water tank 208 is elastically supported by the suspension 209 so that its central axis is located on a slightly inclined axis that descends toward the rear in FIG.

  A motor 210 is provided outside the back surface of the water tank 208. The motor 210 is constituted by, for example, a DC brushless motor, is an outer rotor type, and includes a stator 211 and a rotor 212. The stator 211 is fixed to the outside of the back surface portion of the water tank 208. A rotation shaft 213 is provided at the center of the rotor 212. The rotating shaft 213 is supported by the bearing bracket 214 via the bearing 215 and is inserted into the water tank 208. Inside the water tank 208, there is provided a bottomed cylindrical drum 216 whose bottom side, which is the bottom, is closed.

  The drum 216 is made of metal such as stainless steel. The drum 216 is fixed at the center of the back surface of the drum 216 to the tip of the rotating shaft 213 of the motor 210, and is provided so as to be rotatable about the axis of the water tank 208, that is, the axis inclined downward toward the rear. In this case, the motor 210 functions as a driving device that rotates the drum 216. A reinforcing member 217 for reinforcing the back surface of the drum 216 is provided on the bottom of the drum 216, in other words, on the outer surface of the back surface. The reinforcing member 217 is made of metal such as aluminum die cast. A large number of holes 218 are formed in the peripheral wall portion constituting the drum portion of the drum 216 over the entire area. These holes 218 pass through the peripheral wall portion of the drum 216 and allow water and air to pass therethrough. In addition, a plurality of synthetic resin baffles 219 for picking up laundry are provided on the inner peripheral portion of the drum 216. The water tank 208 may be provided so that its central axis is positioned on a horizontal axis that does not incline. In this case, the drum 216 is provided so as to be rotatable about the horizontal axis.

  Each of the drum 216 and the water tank 208 is open on the front side, and has an opening 220 and an opening 221. Around the opening 220 of the drum 216, a synthetic resin balance ring 222 in which a liquid such as salt water is enclosed is provided. The balance ring 222 is fixed from the outer surface side of the drum 216 by a metal screw (not shown) made of, for example, stainless steel. The opening 221 of the water tank 208 is connected to the laundry entrance / exit 204 through an annular bellows 223 made of an elastic material such as rubber. Thereby, the laundry entrance / exit 204 is connected to the inside of the drum 216 via the bellows 223, the opening 221 of the water tank 208, and the opening 220 of the drum 216.

  A drain outlet 224 is provided at the bottom on the back side of the water tank 208. One end of an in-machine drain hose 225 is connected to the drain outlet 224. The other end of the in-machine drain hose 225 is connected to a filter case 226 provided at the front of the base 202 of the outer box 201. A cap 227 is detachably attached to the front end of the filter case 226. Inside the filter case 226 is housed a lint filter (not shown) that is provided integrally with the cap 227. A drain valve 228 is connected to the lower part of the filter case 226. A drain pipe 229 is connected to the outlet of the drain valve 228. The distal end of the drainage pipe 229 is led out of the machine from the base 202 of the outer box 201 and connected to an unshown drainage hose (not shown).

  An air trap 230 is provided above the filter case 226. The air trap 230 and the water level sensor 231 disposed in the upper part of the outer box 201 are connected by an air tube 232. The water level sensor 231 detects the water level in the water tank 208 via the in-machine drain hose 225, the filter case 226, the air trap 230, and the air tube 232, and outputs it to the control device 207.

  A water supply valve 233 and a water supply case 234 are provided in the upper part of the outer box 201. An external water supply hose extending from a faucet (not shown) is connected to the inlet of the water supply valve 233. One end of a connection pipe 235 is connected to the outlet of the water supply valve 233. The other end of the connection pipe 235 is connected to the water supply case 234. A detergent storage section (not shown) is provided inside the water supply case 234. One end of an in-machine water supply hose 236 is connected to the water supply case 234. The other end of the in-machine water supply hose 236 is connected to the upper part of the water tank 208. Water supplied from the water supply through the water supply valve 233 is supplied into the water tank 208 through the connection pipe 235, the water supply case 234, and the in-machine water supply hose 236.

  For example, as shown in FIG. 1, in the washing machine 100 described above, an antifouling coating 300 is applied to at least the outer surface of the body member 104 a constituting the side portion of the rotating tub 104. In this case, the antifouling coating 300 is provided on the entire outer surface of the copper member 104 a, that is, the side portion of the rotating tub 104. For example, as shown in FIG. 2, the washing machine 200 described above is provided with an antifouling coating 300 on at least the outer surface of the side portion of the drum 216. In this case, the antifouling coating 300 is provided on the entire outer surface of the side portion of the drum 216. Although not shown, particularly in the washing machine 100, antifouling coating is applied to the portion of the dehydrating shaft 113a that protrudes into the water tank 208 and the portion of the washing shaft 113b that protrudes into the water tank 208, respectively. Has been.

  In this embodiment, the antifouling coating 300 is realized by a hydrophilic coating. Next, the case where the antifouling coating 300 is realized by a hydrophilic coating will be described in more detail. That is, when the antifouling coating 300 is realized by, for example, a hydrophilic coating, for example, a silica-based inorganic paint such as a silica-based inorganic paint (hereinafter referred to as “hydrophilic material”) is applied to the outer surface of the side portion of the drum 216. Or it sprays on the outer surface of the side part of the rotation tank 104, and forms a coating.

  When the antifouling coating 300 is realized by, for example, a hydrophilic coating, in this embodiment, a hydrophilic material that forms the antifouling coating 300 having at least the following performance is applied. That is, the antifouling coating 300 of this embodiment has a hydrophilic performance such that the contact angle of water is less than the lower limit value of the contact angle of water with respect to glass. Generally, the lower limit of the contact angle of water with respect to glass is considered to be 20 degrees. Therefore, in the present embodiment, a hydrophilic material that forms the antifouling coating 300 having a water contact angle of less than 20 degrees, for example, 13 degrees, is applied.

  In this embodiment, a material containing silicon oxide is applied as the hydrophilic material forming the antifouling coating 300, and the antifouling coating 300 formed from this hydrophilic material has at least a pencil hardness of 5H or more. It has the following hardness characteristics. That is, the antifouling coating 300 of this embodiment has a strong structure formed of a so-called siloxane skeleton and an alkali metal or an alkaline earth metal, whereby the antifouling coating 300 has a pencil hardness of 5H or more. It has a strong structure.

  Further, the antifouling coating 300 of the present embodiment has a silanol group and has extremely high hydrophilic performance. Specifically, the antifouling coating 300 has such hydrophilic performance that a general oil-based ink attached to the antifouling coating 300 can be removed only by contacting with water. Therefore, even when general oil-based pen ink is attached to the antifouling coating 300, the ink is peeled off and removed by bringing the ink into contact with water so that the ink floats.

  Further, the antifouling coating 300 of the present embodiment has a thickness of 10 μm or less, and its film thickness is extremely thin. That is, in general, when it is desired to improve the hydrophilic performance, it is necessary to repeat the coating of the hydrophilic material. Therefore, the thickness of the obtained hydrophilic performance portion tends to increase. In the present embodiment, a hydrophilic material is used in which the antifouling coating 300 having extremely high hydrophilic performance is formed by one coating and baking of the hydrophilic material. Therefore, the antifouling coating 300 having extremely high hydrophilic performance can be formed without repeating the coating of the hydrophilic material, and the film thickness of the antifouling coating 300 can be suppressed to a thickness of 10 μm or less. . In the drawing, for convenience, the film thickness of the antifouling coating 300 is shown to be larger than the actual film thickness.

  The antifouling coating 300 of this embodiment has a so-called surface roughness of 2 μm or less. In this embodiment, a hydrophilic material on which the antifouling coating 300 having an extremely smooth surface is formed is applied. The hydrophilic material applied in the present embodiment is milky white before spraying, but becomes transparent so that milky white is hardly recognized after spraying, and is almost or completely transparent after baking.

  Further, in the washing machine 100, the antifouling coating 300 is provided on the entire outer surface of the side of the rotating tub 104, and in the washing machine 200, the antifouling coating 300 is provided on the entire outer surface of the side of the drum 216. It has been. Therefore, according to the washing machine 100 or the washing machine 200, even if the water level is set at the lowest level among the settable water levels or the water level is lower than that, water is brought into contact with the antifouling coating 300. Can do.

Next, an example of a manufacturing method for manufacturing the washing machine 100 and the washing machine 200 will be described.
(1) An example of the manufacturing method of the vertical axis | shaft type washing machine 100 The manufacturing method of the washing machine 100 is the press processing process illustrated below, a washing process, a draining / drying process, a coating process, a baking process, a bending process, a joining process, It includes a drawing process, a bottom member attaching process, a balance ring attaching process, a rotating tank attaching process, and the like. Hereinafter, each process is demonstrated in order.

≪Press working process≫
This press working process includes at least a cutting process, a hole forming process, and a protrusion forming process. For example, as shown in FIG. 3, in the cutting step, a plate material Sa serving as a base material for forming the rotating tub 104 is obtained from a metal base material S made of, for example, stainless steel. That is, the metal base material S is sequentially fed by the feeder 401 and is sequentially cut by press working by the cutting machine 402. Thereby, the board | plate material Sa cut | disconnected by the predetermined magnitude | size in order to form the rotation tank 104 is obtained.

  For example, as shown in FIG. 4, in the hole forming step, a hole 105a is formed in the plate material Sa by press working with a punching machine (not shown). The hole 105 a penetrates the plate material Sa, and functions as a hole that allows ventilation and water passage in the rotating tank 104. Further, in the protrusion forming step, the protrusion 105b is formed on the plate material Sa by pressing by a protrusion forming machine (not shown). The protrusion 105 b protrudes inside the rotating tank 104 in the rotating tank 104, but may protrude outside the rotating tank 104.

  By this pressing process, a plate material Sa cut into a predetermined size and having holes 105a and protrusions 105b formed therein is obtained. Note that the order of performing the cutting step, the hole forming step, and the protrusion forming step can be changed as appropriate. For example, the hole forming step may be performed after the protrusion forming step. Moreover, you may implement a cutting process after a hole formation process and a protrusion formation process. Moreover, you may implement a cutting process, a hole formation process, and a protrusion formation process simultaneously. Moreover, when the obtained board | plate material Sa is loaded and transported on a trolley | bogie, a truck, etc., it is good to affix the protective sheet comprised, for example with a vinyl sheet etc. on the surface of board | plate material Sa.

≪Cleaning process≫
In this cleaning process, the plate material Sa obtained by the press working process is cleaned. In addition, when the protective sheet is affixed on board | plate material Sa, the peeling process which peels off the said protective sheet from board | plate material Sa is performed prior to this washing | cleaning process. In this cleaning process, since the plate material Sa is made of stainless steel, it is possible to degrease the plate material Sa using a strong alkaline degreasing agent such as PH14. Therefore, the oil and fat component can be almost or reliably removed from the surface of the plate material Sa by the cleaning effect of the strong alkaline degreasing agent.

≪Draining / drying process≫
In this draining / drying step, the degreasing agent remaining on the plate material Sa is removed, for example, by wiping. Further, the plate material Sa is dried by a dryer (not shown).

≪Coating process≫
In this coating process, in this case, the hydrophilic material is sprayed on the entire surface of the plate material Sa that forms the outer surface of the side portion of the rotating tank 104. Thereby, a hydrophilic material is coated on the whole surface which forms the outer surface of the side part of the rotation tank 104 among board | plate materials Sa. Therefore, for example, as shown in FIG. 5, the joints Ra and Rb set at both ends in the longitudinal direction of the plate material Sa, and the molding set at both ends in the short direction perpendicular to the longitudinal direction of the plate material Sa. A hydrophilic material is applied to the entire surface including the processed portions Rc and Rd. In this case, if the oil and fat component is sufficiently removed in the above-described cleaning step, the sprayed hydrophilic material is easily adapted to the surface of the plate material Sa. In addition, you may implement the hole formation process or protrusion formation process mentioned above after this coating process.

≪Baking process≫
In this baking process, the hydrophilic material painted on the plate material Sa is baked at a predetermined temperature. Note that the baking temperature of the hydrophilic material is preferably set at a temperature higher than 250 ° C., which is generally considered to be a temperature at which organic matter is decomposed, and may be set at a temperature of 300 ° C. or 500 ° C., for example. . By baking the hydrophilic material at such a high temperature, the organic matter contained in the hydrophilic material can be almost or completely decomposed, and the almost or completely inorganic antifouling coating 300 can be formed. . Thereby, the board | plate material Sa by which the antifouling coating 300 was given to the whole surface which forms the outer surface of the side part of the rotation tank 104 is obtained. In addition, when the obtained board | plate material Sa is loaded and transported on a trolley | bogie, a truck, etc., it is good to stick a protective sheet on the surface of board | plate material Sa.

≪Bending process≫
In this bending step, for example, as shown in FIG. 6, the plate material Sa provided with the antifouling coating 300 is bent into a cylindrical shape by a bending machine 501. In addition, when the protective sheet is affixed on board | plate material Sa, the peeling process which peels off the said protective sheet from board | plate material Sa is performed prior to this bending process. In this case, the bending machine 501 is configured to bend the plate material Sa into a cylindrical shape by feeding both sides of the plate material Sa, that is, both the coated surface and the uncoated surface of the hydrophilic material. Note that the time required for bending the plate material Sa by the bending machine 501 can be performed in, for example, about 2 to 3 seconds, but the time can be changed as appropriate. Moreover, you may implement the above-mentioned baking process after this bending process.

≪Join process≫
In this joining step, for example, as shown in FIG. 7, both ends in the longitudinal direction of the plate material Sa bent in a substantially cylindrical shape by the bending step, that is, the ends of the joining portions Ra and Rb are joined. In this case, joining of both ends in the longitudinal direction of the plate material Sa is performed by caulking. Here, this caulking mode will be described. That is, for example, as shown in FIG. 8, the front ends of both end portions in the longitudinal direction of the plate material Sa are bent so as to have a U-shaped cross section, and these front ends are engaged with each other. Then, for example, as shown in FIG. 9, in a state in which both ends in the longitudinal direction of the plate material Sa are engaged with each other, the engaging portion has a corrugated cross section along the axial direction of the cylindrical plate material Sa. Let's transform. Thereby, the both ends of the longitudinal direction of board | plate material Sa are joined by caulking. And the cylindrical intermediate body 104S which is the original form of the rotation tank 104 is obtained.

  In this case, the caulking of both ends of the plate material Sa may be advanced in the direction from the upper part to the lower part in the rotating tank 104, that is, in the direction of the arrow Ya shown in FIG. You may advance in the direction which goes from the part used as a side to the part used as an upper side, ie, the arrow Yb direction shown in FIG. Further, most of the portions where the engaging portions where the both ends of the plate material Sa are engaged are deformed in a wave shape are concentrated between the forming portion Rc and the forming portion Rd. There are zero places in the molding part Rc. Note that the distribution of locations where the engaging portion is deformed in a wave shape is uniformly distributed along the axial direction of the cylindrical plate material Sa, for example, while being concentrated between the forming portion Rc and the forming portion Rd. The distribution can be appropriately adjusted, for example, by providing several portions in the portion Rc and the molding processing portion Rd.

  According to the intermediate body 104S of the rotating tank 104 manufactured in this way, the antifouling coating 300 is formed on the entire surface of the plate material Sa including the joint portions Ra and Rb before this joining step. Therefore, the outer surface of the intermediate body 104S is provided with the antifouling coating 300 on the entire surface including the caulking portion.

≪Drawing process≫
In this drawing process, drawing is performed in order to deform part of the cylindrical plate material Sa, that is, the intermediate body 104S obtained by the joining process by caulking. That is, for example, as shown in FIG. 10, the shape of the molding parts Rc, Rd is narrowed inward by pressing an unillustrated roller or the like from the outer surface side to the part of the intermediate body 104S consisting of the molding parts Rc, Rd. Thereby, the balance ring mounting portion 104Sa is formed in the upper part of the intermediate body 104S, that is, the upper part in the rotary tank 104, and the bottom part in the lower part of the intermediate body 104S, that is, the lower part in the rotary tank 104. A material mounting portion 104Sb is formed. In FIG. 10, the antifouling coating 300 is not shown.

≪Bottom member attachment process≫
In this attachment step, the bottom member 104b is attached to the bottom member attachment portion 104Sb provided on the lower side of the intermediate body 104S. That is, for example, as shown in FIG. 11, the bottom member 104b is fitted inside the bottom member attachment portion 104Sb. And the lower end of bottom member attaching part 104Sb is bend | folded inside, and it is made to latch on the bottom member 104b. Thereby, the bottom member 104b is attached and fixed in the bottom member attaching part 104Sb.

≪Balance ring installation process≫
In this attachment step, the balance ring 106 is attached to the balance ring attachment portion 104Sa provided on the upper side of the intermediate body 104S. That is, for example, as shown in FIG. 12, the balance ring 106 is fitted inside the balance ring mounting portion 104Sa. And screw 106a is screwed in from the outside of balance ring attaching part 104Sa. Thereby, the balance ring 106 is attached and fixed in the balance ring attachment portion 104Sa.

≪Rotating tank installation process≫
The rotating tank 104 is manufactured by attaching the bottom member 104b and the balance ring 106 to the intermediate body 104S. The rotating tub 104 is rotatably mounted in the water tub 102 of the washing machine 100. In addition, illustration of the hole 105a and the protrusion part 105b is abbreviate | omitted in drawing.

(2) Example of Manufacturing Method of Drum-type Washing Machine 200 The manufacturing method of the washing machine 200 includes a press process, a washing process, a draining / drying process, a bending process, a joining process, a diameter expanding process, and a back plate as exemplified below. It includes an attaching process, a coating process, a baking process, a balancing ring attaching process, a rotating tank attaching process, and the like. Hereinafter, each process is demonstrated in order.

≪Pressing process≫ ・ ≪Cleaning process≫ ・ ≪Draining / drying process≫
Since the pressing process, the washing process, and the draining / drying process are the same as the above-described pressing process, the cleaning process, and the draining / drying process, respectively, description thereof is omitted.

≪Bending process≫
In this bending step, the plate material Sa is bent into a cylindrical shape by a bending machine 501. That is, in this case, the plate material Sa to which the antifouling coating 300 is not applied is bent into a cylindrical shape. In addition, when the protective sheet is affixed on board | plate material Sa, the peeling process which peels off the said protective sheet from board | plate material Sa is performed prior to this bending process.

≪Join process≫
Since the joining process is the same as the joining process by caulking described above, description thereof is omitted.
≪Diameter enlargement process≫
This diameter expansion process is also referred to as an expanding process. That is, in this diameter expansion process, the diameter dimension of the cylindrical plate material Sa, that is, the intermediate body 216S obtained by the joining process is expanded. That is, for example, as indicated by an arrow E in FIG. 13A, from the inner side of the intermediate body 216S, a particularly intermediate portion of the intermediate body 216S is pushed outward by a spreader (not shown). Thereby, for example, as shown in FIG. 13B, the diameter of the intermediate body 216S, in particular, the intermediate portion can be slightly enlarged. In the drawings, for the convenience of explanation, the enlargement amount of the diameter dimension is exaggerated from the actual one.

≪Back plate installation process≫
In this attachment step, for example, as shown in FIG. 14, the back plate 216H is attached to the intermediate body 216S. That is, a metal back plate 216H made of, for example, stainless steel is fitted into one end of the intermediate 216S. Then, a screw (not shown) is screwed in from the outside of the intermediate body 216S. Thereby, the back plate 216H is attached and fixed in one end portion of the intermediate body 216S. The back plate 216H constitutes the back of the drum 216. In the washing machine 200, the rotating shaft 213 of the motor 210, the reinforcing member 217, and the like are attached.

≪Coating process≫
In this coating step, in this case, a hydrophilic material is sprayed onto the entire outer surface of the side portion of the intermediate 216S, that is, the entire surface forming the outer surface of the side portion of the drum 216. That is, for example, as shown in FIG. 15, the intermediate body 216S to which the back plate 216H is attached is placed on the turntable 601 with the side to which the back plate 216H is attached facing up, for example. And while rotating the intermediate body 216S with the rotary table 601, a hydrophilic material is sprayed on the outer surface of the said intermediate body 216S. Thereby, a hydrophilic material is coated on the surface forming the outer surface of the side portion of the drum 216. In this case, the hydrophilic material is sprayed on the intermediate part 216S so as to cover the part joined by caulking or the part screwed.

≪Baking process≫
Since the baking process is the same as the baking process described above, the description thereof is omitted.
≪Balance ring installation process≫
In this attachment process, the balance ring 222 is attached to the intermediate body 216S. That is, the balance ring 222 is fitted into the end of the intermediate body 216S opposite to the side on which the back plate 216H is attached. Then, a screw (not shown) is screwed in from the outside of the intermediate body 216S. Thereby, the balance ring 222 is attached and fixed to the intermediate body 216S.

≪Rotating tank installation process≫
The drum 216 is manufactured by attaching the balance ring 222 to the intermediate body 216S. The drum 216 is rotatably mounted in the water tub 208 of the washing machine 200. In addition, illustration of the hole 218 etc. is abbreviate | omitted in drawing.

  According to the washing machines 100 and 200 according to the present embodiment, the antifouling coating 300 having an antifouling function is applied to the outer surfaces of the side portions of the rotary tubs 104 and 216 that are rotatably provided in the water tanks 102 and 208. ing. According to this configuration, the outer surfaces of the side portions of the rotary tubs 104 and 216 that cannot be easily reached due to the lack of reach can be kept clean by the antifouling function of the antifouling coating 300, and the washing machine In 100 and 200, the antifouling function can be utilized most effectively.

  Moreover, according to the washing machines 100 and 200 according to this embodiment, the antifouling coating 300 is a hydrophilic coating having extremely high hydrophilic performance. Therefore, water easily enters between the dirt attached to the antifouling coating 300 and the surface of the antifouling coating 300, and the dirt adhering to the antifouling coating 300 is lifted or peeled off. Can be removed. In addition, the outer surfaces of the side portions of the rotating tubs 104 and 216 that cannot be easily maintained due to the lack of reach can be kept clean by the antifouling function due to the hydrophilic property of the antifouling coating 300, and the washing machine 100. 200, the antifouling function due to hydrophilicity can be most effectively utilized.

  Moreover, according to the washing machines 100 and 200, the antifouling coating 300 is provided on the outer surface of the side of the rotating tubs 104 and 216. Therefore, when the rotating tanks 104 and 216 are rotated, dirt peeled off from the surfaces of the rotating tanks 104 and 216 is easily removed due to the action of centrifugal force, and the surfaces of the rotating tanks 104 and 216 are maintained more cleanly. can do.

  Moreover, according to the washing machines 100 and 200, the antifouling coating 300 is provided on the entire outer surface of the side portion of the rotary tubs 104 and 216. Therefore, the entire outer surfaces of the side portions of the rotary tanks 104 and 216 can be kept clean by the antifouling function of the antifouling coating 300. Moreover, according to the washing machines 100 and 200, since the rotating tubs 104 and 216 are made of metal instead of synthetic resin, a hydrophilic material can be coated on the outer surface of the metal portion of the rotating tubs 104 and 216 by baking. . This makes it possible to form a highly inorganic and strong and durable antifouling coating 300.

  Moreover, according to the washing machines 100 and 200, the antifouling coating 300 has a water contact angle that is less than the lower limit value of the water contact angle with respect to glass, and has a silanol group. Therefore, the antifouling coating 300 exhibits extremely high hydrophilic performance. This makes it easy for water to enter between the surface of the antifouling coating 300 and the dirt adhering to the antifouling coating 300, and the dirt adhering to the antifouling coating 300 can be removed so as to float up.

  In addition, according to the washing machines 100 and 200, the antifouling coating 300 has silicon oxide and has a hardness characteristic such that the pencil hardness is 5H or more. Therefore, it is possible to prevent the antifouling coating 300 from being damaged or the antifouling coating 300 from being peeled off. Moreover, according to the washing machines 100 and 200, the antifouling coating 300 has a thickness of 10 μm or less, and an extremely thin antifouling coating 300 is realized. Moreover, according to the washing machines 100 and 200, the antifouling coating 300 has a surface roughness of 2 μm or less, and an extremely smooth antifouling coating 300 is realized.

In particular, according to the washing machine 100, the dehydrating shaft 113a and the washing shaft 113b for transmitting the rotational force of the motor to the rotating tub 104 or the stirring body 107 are also provided with hydrophilic coatings. Therefore, the dehydrating shaft 113a or the washing shaft 113b can be maintained in a sanitary manner, and as a result, the inside of the tank can be maintained in a sanitary manner.
Moreover, according to the washing machine 100, the water flow path 119 provided with the disinfectant unit 120 is provided so as to face the joint portion by caulking of the rotating tub 104. Therefore, the sanitary effect by a disinfectant can be given to the joint by caulking.

  Moreover, according to the manufacturing method of the washing machine which concerns on this embodiment, the washing machines 100 and 200 to which the antifouling coating of the stable quality was given can be provided. In particular, according to the manufacturing method in which the antifouling coating is formed before bending the plate material Sa, the plate material Sa on which the antifouling coating is applied can be handled in a flat plate shape, for example, by stacking and transporting a plurality of plate materials Sa. It is possible to improve the ease of handling and workability.

  Further, if the coating process is performed after the pressing process, the antifouling coating 300 can be formed also on the tip surface of the hole formed in the plate material Sa and the tip part of the protrusion. That is, the uniform antifouling coating 300 can be formed on the deformed portion of the outer surface of the side of the rotary tank 104 or the drum 216 as well as other planar portions. Further, when holes or protrusions are formed in the plate material, an excessive load may be applied to the plate material. Therefore, by performing the coating process after the process in which an excessive load is applied to the plate material as described above, it is possible to avoid an excessive load being applied to the antifouling coating to be formed.

  The pressing process is a process that is performed at a relatively upstream stage in the process of manufacturing a general rotating tank that is not subjected to antifouling coating. Therefore, if the coating process is performed prior to the pressing process, the processes after the pressing process can be advanced by a manufacturing process for manufacturing a general rotating tank not subjected to the antifouling coating. . Therefore, it is not necessary to change the existing manufacturing process, and all processes including the coating process can be simplified. Moreover, since the process after a press work process can be advanced by the existing manufacturing process, the fall of work efficiency can be avoided.

  The washing machine 100 may further include a metal screw 106 a attached to the rotating tub 104 or an antifouling coating 300 on the inner surface of the rotating tub 104. In addition, the washing machine 200 may further include a metal screw attached to the drum 216 or an antifouling coating 300 on the inner surface of the drum 216. That is, the portion where the antifouling coating 300 is formed in the present embodiment is not limited to the outer surface of the side portion of the rotating tub 104 or the outer surface of the side portion of the drum 216. When the antifouling coating 300 is formed on a metal screw, it is not necessary to form the antifouling coating 300 on the entire screw, and it is sufficient if the antifouling coating 300 is formed on the surface of the screw head that is the outer surface. It is. Further, when the antifouling coating 300 is formed on the inner surface of the rotating tank 104 or the drum 216, the antifouling coating 300 may be formed on the entire inner surface, or the hydrophilic performance portion 300 may be formed on a part of the inner surface. Also good.

  Further, the antifouling coating 300 may be colored. That is, as the hydrophilic material for forming the antifouling coating 300, a material that retains color after spraying or baking onto the base material may be applied. Thereby, it can be easily confirmed visually whether or not the formed antifouling coating 300 is uneven. For example, a rotating tank in which the antifouling coating 300 is not uniformly formed is regarded as a defective product. Can be identified.

Further, in the washing machines 100 and 200, water is stored in the water tanks 102 and 208 after the washing course including the washing process, the rinsing process, the dehydrating process, etc. or during the execution of the washing course, so that the rotating tank 104 and the drum 216 are stored. You may set so that the washing process which rotates may be performed. In this cleaning process, when the water comes into contact with the antifouling coating 300, dirt attached to the antifouling coating 300 can be removed. In this washing process, the amount of water stored in the water tanks 102 and 208 is increased from the washing course, and the rotational speeds of the rotary tank 104 and the drum 216 are set at a speed higher than the rotational speed in the washing process or the rinsing process. Good.
Moreover, according to the washing machines 100 and 200, the antirust effect by the antifouling coating 300 can also be expected.

(Other embodiments)
The present embodiment is not limited to the above-described embodiment, and can be expanded or modified as follows, for example.
The antifouling coating is not limited to the hydrophilic coating that exhibits the antifouling function due to hydrophilicity, and may be, for example, a water repellent coating that exhibits the antifouling function due to water repellency. In this case, in the coating process, a coating material having water repellency, that is, a water-repellent coating material is sprayed onto the surface of the plate material that forms the outer surface of the side portion of the rotating tub.

  The antifouling coating may be provided on a part of the outer surface of the side portion of the rotating tub instead of being provided on the entire outer surface of the side portion of the rotating tub. Further, the antifouling coating may be provided on the outer surface of the rear surface or the outer surface of the bottom surface of the rotating tank. In this case, the antifouling coating may be provided on the entire outer surface of the back surface portion of the rotating tank, or may be provided on a part thereof. Further, the antifouling coating may be provided on the entire outer surface of the bottom surface of the rotating tank or may be provided on a part thereof. The antifouling coating may be provided on a reinforcing member that reinforces the rotating tub. In this case, the antifouling coating may be provided on the entire reinforcing member or a part thereof. Moreover, you may provide antifouling coating in the several through-hole formed in the rotation tank.

  The step of applying the antifouling coating to the dehydrating shaft 113a and the washing shaft 113b can be performed at an appropriate timing, for example, before or after the dehydrating shaft 113a and the washing shaft 113b are assembled. Moreover, when applying antifouling coating to components other than the rotary tub with which a washing machine is equipped, the process of applying antifouling coating can be implemented at the appropriate timing before the assembly | attachment of the component.

Moreover, the execution order and combination of each manufacturing process mentioned above can be changed suitably.
Moreover, in the above-mentioned embodiment, although the structure which gives antifouling coating to the whole outer surface of the side part of a rotation tank was illustrated, antifouling coating is the part joined by caulking at least among the outer surfaces of the side part of a rotation tank If it is the structure given to, it can implement by adjusting the formation area of the coating suitably.

  The washing machine according to the present embodiment described above is a washing machine in which side portions of a rotating tub provided rotatably in a water tub are formed by caulking and joining both end portions of a metal plate, An antifouling coating having an antifouling function is applied to at least a portion joined by caulking of the outer surface of the side portion of the rotating tub.

  Moreover, the manufacturing method of the washing machine which concerns on this embodiment manufactures the washing machine which formed the side part of the rotation tank provided rotatably in the water tank by crimping and joining the both ends of metal board | plate materials. A method of forming an antifouling coating having an antifouling function on at least a portion of the outer surface of the side portion of the rotating tank joined by caulking before or after the joining step of caulking and joining the both ends of the plate material The coating process is performed.

  According to the washing machine or the manufacturing method of the washing machine according to the present embodiment, the outer surface of the rotating tub, which is a part that cannot be easily reached and cannot be easily maintained in the washing machine, can be kept clean. The antifouling function by the antifouling coating can be utilized most effectively.

  Moreover, according to the washing machine which concerns on this embodiment, or the manufacturing method of a washing machine, the both ends of the board | plate material were joined by caulking. Therefore, for example, both ends of the plate material can be easily joined as compared with joining by welding, and the production efficiency can be improved and the production cost can be reduced. In addition, when both ends of the plate material are joined by welding, it is preferable that the both ends are not coated. However, when both ends of the plate material are joined by caulking, the both ends are coated. It does not matter. Therefore, the antifouling coating can be applied over a wide range including both ends of the plate material. As a result, the antifouling coating can be formed over a wide range of the outer surface of the side portion of the rotating tank.

  In addition, the portion joined by caulking of the outer surface of the side portion of the rotating tank is particularly prone to adhere to such uneven portions because the shape deformation such as concavities and convexities is larger than when joined by welding, Moreover, the attached dirt is difficult to remove. According to this embodiment, at least such a caulking joint is provided with an antifouling coating. Therefore, the antifouling function by the antifouling coating can be utilized more effectively.

Further, according to the present embodiment, a washing machine in which an antifouling coating is applied to at least a portion joined by caulking of the outer surface of the side portion of the rotating tub by performing a joining step by caulking after the coating step. Can be manufactured stably and efficiently.
In addition, according to the present embodiment, a washing machine in which an antifouling coating is applied to at least a portion joined by caulking of the outer surface of the side portion of the rotating tub by performing a coating step after the joining step by caulking. Can be manufactured stably and efficiently.

Moreover, according to this embodiment, antifouling coating is given also to the part to which drawing processing is performed in order to attach another components, such as a balance ring and a bottom member, among rotation tanks. Therefore, the antifouling function by the antifouling coating can be exhibited over a wide range of the outer surface of the side portion of the rotating tub including such a drawn portion.
In addition, according to the present embodiment, the antifouling function over a wide area of the outer surface of the side of the rotating tub including the drawn portion by performing the coating process before or after the processing step of drawing the part of the rotating tub. A washing machine capable of exhibiting the above can be manufactured stably and efficiently.

  Moreover, according to the washing machine by this embodiment, it is possible to manufacture by implementing the bending process which bends a board | plate material cylindrically after a coating process. Therefore, when manufacturing the washing machine, it is possible to handle the plate material coated with antifouling coating in a flat shape, for example, it is possible to stack and transport a plurality of plate materials, Workability can be improved.

  Further, according to the washing machine according to the present embodiment, after the coating process and before the bending process of bending the plate material into a cylindrical shape, the baking process of baking the coating material attached to the plate material in the coating process. It is possible to manufacture by implementing. Thereby, after forming a strong antifouling coating, a board | plate material can be bent and the damage of the antifouling coating accompanying bending of a board | plate material can be suppressed.

  Moreover, according to the washing machine which concerns on this embodiment, it is possible to manufacture by implementing a coating process after the bending process which bends a board | plate material to cylindrical shape. Moreover, according to a washing machine, it is possible to manufacture by performing the baking process which bakes the coating material adhering to the board | plate material in the said coating process after the bending process which bends a board | plate material in cylindrical shape. Thus, even if a strong antifouling coating is formed after bending the plate material, damage to the antifouling coating can be suppressed.

Moreover, according to the washing machine which concerns on this embodiment, it is possible to manufacture by implementing the joining process which joins the both ends of a board | plate material after a bending process and before a coating process. . Thereby, an antifouling coating can be formed also on the surface of the part to be joined.
Moreover, according to the washing machine which concerns on this embodiment, it is possible to manufacture by implementing the baking process which bakes the coating material adhering to the board | plate material in the said coating process after the coating process. Thereby, a strong antifouling coating can be formed.

  Moreover, according to the washing machine which concerns on this embodiment, it is possible to manufacture by implementing the baking process which bakes the coating material adhering to the board | plate material in the coating process after the diameter expansion process and the coating process. That is, by forming a strong antifouling coating after a process that requires an excessive load, damage to the antifouling coating can be suppressed.

Moreover, according to the washing machine which concerns on this embodiment, it is good to give antifouling coating also to the part which protrudes in a water tank among the rotating tank rotating shafts for rotating a rotating tank. Moreover, according to the washing machine which concerns on this embodiment, when antifouling coating is given also to the part which protrudes in a water tank among the stirring body rotating shafts for rotating the stirring body rotatably provided in the rotating tank, Good. Thereby, the rotating tank rotating shaft and the stirring body rotating shaft can be maintained in a sanitary manner, and thus the inside of the tank can be maintained in a sanitary manner.
Moreover, according to the manufacturing method of the washing machine which concerns on this embodiment, the washing machine which has an advantageous effect as mentioned above can be manufactured stably and efficiently.

  This embodiment is presented as an example and is not intended to limit the scope of the invention. These novel embodiments can be implemented in various other forms, and various omissions, replacements, and changes can be made without departing from the scope of the invention. This embodiment and its modifications are included in the scope and gist of the invention, and are included in the invention described in the claims and the equivalents thereof.

  In the drawings, 100 and 200 are washing machines, 102 and 208 are water tanks, 104 is a rotating tank, 216 is a drum (rotating tank), and 300 is a hydrophilic coating (antifouling coating).

Claims (10)

A washing machine in which the sides of a rotating tub that is rotatably provided in the water tub are formed by caulking and joining both ends of a metal plate,
A washing machine in which an antifouling coating having an antifouling function is applied to at least a portion joined by caulking of the outer surface of the side portion of the rotating tub.   The washing machine according to claim 1, wherein after the antifouling coating is applied to at least both ends of the plate material, the side portions of the rotating tub are formed by caulking and joining the both ends of the plate material.   The antifouling coating is applied to at least a portion joined by caulking of the outer surface of the side portion of the rotating tub after the side portions of the rotating tub are formed by caulking and joining both ends of the plate material. The washing machine according to 1.   Of the rotating tank formed by caulking and joining both ends of the plate material, a drawing process is applied to a portion to which a balance ring is attached, and the antifouling coating is also applied to the drawing process portion. The washing machine according to any one of claims 1 to 3.   Of the rotating tub formed by caulking and joining both ends of the plate material, a drawing process is applied to a portion to which a bottom member forming the bottom of the rotating tub is attached, The washing machine according to any one of claims 1 to 4, wherein an antifouling coating is applied. A method of manufacturing a washing machine in which a side portion of a rotating tub provided rotatably in a water tub is formed by caulking and joining both end portions of a metal plate material,
A coating step for forming an antifouling coating having an antifouling function on at least a portion joined by caulking of the outer surface of the side portion of the rotating tank before or after the joining step of caulking and joining the both ends of the plate material A method for manufacturing a washing machine.   The method for manufacturing a washing machine according to claim 6, wherein the coating step is performed before the joining step, and the antifouling coating is applied to at least both ends of the plate material in the coating step.   The said coating process is performed after the said joining process, In this coating process, the said antifouling coating is given to the part joined by caulking among the outer surfaces of the side part of the said rotary tank, The manufacturing of the washing machine of Claim 6 Method.   The method further includes a processing step of drawing a portion of the rotating tub formed by caulking and joining both ends of the plate material to which a balance ring is attached, and performing the coating step before or after the processing step. Item 9. The method for manufacturing a washing machine according to any one of Items 6 to 8.   The method further includes a processing step of drawing a portion of the rotating tub formed by caulking and joining both end portions of the plate material to a portion to which a bottom member forming the bottom of the rotating tub is attached. Or the manufacturing method of the washing machine of any one of Claim 6 to 9 which performs the said coating process later.

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