WO2014203969A1 - 洗濯機および洗濯機の製造方法 - Google Patents
洗濯機および洗濯機の製造方法 Download PDFInfo
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- WO2014203969A1 WO2014203969A1 PCT/JP2014/066295 JP2014066295W WO2014203969A1 WO 2014203969 A1 WO2014203969 A1 WO 2014203969A1 JP 2014066295 W JP2014066295 W JP 2014066295W WO 2014203969 A1 WO2014203969 A1 WO 2014203969A1
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- washing machine
- coating
- plate material
- machine according
- manufacturing
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- D—TEXTILES; PAPER
- D06—TREATMENT OF TEXTILES OR THE LIKE; LAUNDERING; FLEXIBLE MATERIALS NOT OTHERWISE PROVIDED FOR
- D06F—LAUNDERING, DRYING, IRONING, PRESSING OR FOLDING TEXTILE ARTICLES
- D06F37/00—Details specific to washing machines covered by groups D06F21/00 - D06F25/00
- D06F37/02—Rotary receptacles, e.g. drums
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- D—TEXTILES; PAPER
- D06—TREATMENT OF TEXTILES OR THE LIKE; LAUNDERING; FLEXIBLE MATERIALS NOT OTHERWISE PROVIDED FOR
- D06F—LAUNDERING, DRYING, IRONING, PRESSING OR FOLDING TEXTILE ARTICLES
- D06F37/00—Details specific to washing machines covered by groups D06F21/00 - D06F25/00
- D06F37/26—Casings; Tubs
- D06F37/261—Tubs made by a specially selected manufacturing process or characterised by their assembly from elements
-
- D—TEXTILES; PAPER
- D06—TREATMENT OF TEXTILES OR THE LIKE; LAUNDERING; FLEXIBLE MATERIALS NOT OTHERWISE PROVIDED FOR
- D06F—LAUNDERING, DRYING, IRONING, PRESSING OR FOLDING TEXTILE ARTICLES
- D06F23/00—Washing machines with receptacles, e.g. perforated, having a rotary movement, e.g. oscillatory movement, the receptacle serving both for washing and for centrifugally separating water from the laundry
- D06F23/02—Washing machines with receptacles, e.g. perforated, having a rotary movement, e.g. oscillatory movement, the receptacle serving both for washing and for centrifugally separating water from the laundry and rotating or oscillating about a horizontal axis
-
- D—TEXTILES; PAPER
- D06—TREATMENT OF TEXTILES OR THE LIKE; LAUNDERING; FLEXIBLE MATERIALS NOT OTHERWISE PROVIDED FOR
- D06F—LAUNDERING, DRYING, IRONING, PRESSING OR FOLDING TEXTILE ARTICLES
- D06F23/00—Washing machines with receptacles, e.g. perforated, having a rotary movement, e.g. oscillatory movement, the receptacle serving both for washing and for centrifugally separating water from the laundry
- D06F23/04—Washing machines with receptacles, e.g. perforated, having a rotary movement, e.g. oscillatory movement, the receptacle serving both for washing and for centrifugally separating water from the laundry and rotating or oscillating about a vertical axis
-
- D—TEXTILES; PAPER
- D06—TREATMENT OF TEXTILES OR THE LIKE; LAUNDERING; FLEXIBLE MATERIALS NOT OTHERWISE PROVIDED FOR
- D06F—LAUNDERING, DRYING, IRONING, PRESSING OR FOLDING TEXTILE ARTICLES
- D06F23/00—Washing machines with receptacles, e.g. perforated, having a rotary movement, e.g. oscillatory movement, the receptacle serving both for washing and for centrifugally separating water from the laundry
- D06F23/06—Washing machines with receptacles, e.g. perforated, having a rotary movement, e.g. oscillatory movement, the receptacle serving both for washing and for centrifugally separating water from the laundry and rotating or oscillating about an inclined axis
-
- D—TEXTILES; PAPER
- D06—TREATMENT OF TEXTILES OR THE LIKE; LAUNDERING; FLEXIBLE MATERIALS NOT OTHERWISE PROVIDED FOR
- D06F—LAUNDERING, DRYING, IRONING, PRESSING OR FOLDING TEXTILE ARTICLES
- D06F35/00—Washing machines, apparatus, or methods not otherwise provided for
- D06F35/005—Methods for washing, rinsing or spin-drying
- D06F35/008—Methods for washing, rinsing or spin-drying for disinfecting the tub or the drum
-
- D—TEXTILES; PAPER
- D06—TREATMENT OF TEXTILES OR THE LIKE; LAUNDERING; FLEXIBLE MATERIALS NOT OTHERWISE PROVIDED FOR
- D06F—LAUNDERING, DRYING, IRONING, PRESSING OR FOLDING TEXTILE ARTICLES
- D06F37/00—Details specific to washing machines covered by groups D06F21/00 - D06F25/00
- D06F37/02—Rotary receptacles, e.g. drums
- D06F37/12—Rotary receptacles, e.g. drums adapted for rotation or oscillation about a vertical axis
-
- D—TEXTILES; PAPER
- D06—TREATMENT OF TEXTILES OR THE LIKE; LAUNDERING; FLEXIBLE MATERIALS NOT OTHERWISE PROVIDED FOR
- D06F—LAUNDERING, DRYING, IRONING, PRESSING OR FOLDING TEXTILE ARTICLES
- D06F39/00—Details of washing machines not specific to a single type of machines covered by groups D06F9/00 - D06F27/00
- D06F39/12—Casings; Tubs
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- Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
- Y02—TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
- Y02B—CLIMATE CHANGE MITIGATION TECHNOLOGIES RELATED TO BUILDINGS, e.g. HOUSING, HOUSE APPLIANCES OR RELATED END-USER APPLICATIONS
- Y02B40/00—Technologies aiming at improving the efficiency of home appliances, e.g. induction cooking or efficient technologies for refrigerators, freezers or dish washers
Definitions
- Embodiments of the present invention relate to a washing machine and a method for manufacturing the washing machine.
- 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.
- This embodiment provides a washing machine applied to a part where the antifouling function can be most effectively used, and a method of manufacturing the washing machine for producing the washing machine.
- the washing machine of the present embodiment is a washing machine in which a metal plate is bent into a cylindrical shape to form a side portion of a rotating tub that is rotatably provided in the water tub.
- This washing machine is manufactured by performing a coating process of applying an antifouling coating having an antifouling function to the surface of the plate material that forms the outer surface of the side of the rotating tub. Antifouling coating is applied to the outer surface.
- the method for manufacturing a washing machine is a method for manufacturing a washing machine in which a metal plate is bent into a cylindrical shape to form a side portion of a rotating tub that is rotatably provided in a water tub.
- the outer surface of the side portion of the rotating tub is protected by performing a coating step of applying an antifouling coating having an antifouling function to the surface of the plate material forming the outer surface of the side portion of the rotating tub.
- FIG. 1 is a longitudinal side view schematically showing a configuration example of a vertical washing machine according to a first embodiment.
- 1 is a longitudinal sectional view schematically showing a configuration example of a drum type washing machine according to a first 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 an example of a masking process roughly The figure which shows an example of a bending process roughly The figure which shows an example of a joining process roughly The figure which shows the modification of a joining process roughly 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 FIG.
- (a) is an enlarged view of the periphery of a hole showing an example of a configuration not having a hydrophilic performance portion on the end face of the hole
- (b) is an example of a configuration having a hydrophilic performance portion on the end face of the hole.
- 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.
- a bottomed cylindrical rotating tank 104 having an open upper surface is rotatably provided inside the water tank 102.
- 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.
- 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 rotating 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 at the bottom 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.
- 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
- the washing shaft 113b is an example of an agitator rotating shaft.
- 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.
- 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.
- a circular concave region in which the stirring body 107 is disposed is provided on the inner bottom portion of the rotating tank 104.
- a pump chamber 118 is formed between the concave region and the stirring body 107.
- the stirring body 107 has a disc shape having a protrusion on the upper surface for generating a rotating water flow.
- the stirring body 107 has a plurality of water passage holes that vertically penetrate the plate surface.
- 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.
- 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 rotating tub 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.
- 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.
- 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.
- 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.
- 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.
- a control device 207 for controlling the overall operation of the washing machine 200 is provided on the back side of the operation panel 206.
- a bottomed cylindrical water tank 208 is provided in the outer box 201 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.
- 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.
- 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.
- 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.
- the drum 216 and the water tank 208 are both open on the front side, and have an opening 220 and an opening 221.
- 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 of the rear surface 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 on the upper part of 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.
- an antifouling coating 300 is applied to at least the outer surface of the body member 104a constituting the side portion of the rotating tub 104.
- the antifouling coating 300 is formed on substantially the entire outer surface of the side portion of the body member 104a.
- 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.
- the antifouling coating 300 is formed on substantially the entire outer surface of the side portion of the drum 216.
- 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.
- the antifouling coating provided in the washing machine always exhibits an antifouling function.
- the antifouling coating 300 is realized by a hydrophilic coating. Therefore, the antifouling coating always exhibits hydrophilic performance.
- 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.
- the coating can be performed by spraying a hydrophilic material on the outer surface of the drum 216 or the outer surface of the rotating tub 104 and baking the hydrophilic material. Can be.
- degreasing can be performed using a strong alkaline degreasing agent in the degreasing treatment performed before spraying the hydrophilic material. .
- the antifouling coating 300 is realized by, for example, a hydrophilic coating
- 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.
- 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.
- the antifouling coating 300 of the present embodiment has a silanol group, and its hydrophilic performance is extremely high. 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.
- the antifouling coating 300 of the present embodiment has a thickness of 10 ⁇ m 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.
- 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 ⁇ m 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 the present embodiment has a so-called surface roughness of 2 ⁇ m or less.
- 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 becomes almost or completely transparent after baking.
- the antifouling coating 300 is provided in a region higher than the lowest level water level L among the water levels that can be set in the washing machine 100. ing. In the washing machine 100, it is rare that the lowest level water level L is set. Therefore, the washing machine 100 is operated at a higher water level than the lowest level water level L in most cases. Therefore, according to the washing machine 100 which concerns on this embodiment, water can be made to contact the antifouling coating 300 in most driving
- the antifouling coating is generated by generating a flow such as rotation or convection in the water in the water tank 208 by rotating the stirring body 107, for example. Water can reach 300.
- the manufacturing method of the washing machine 100 is the press processing process illustrated below, a washing process, a draining / drying process, a masking process, a coating process, a baking process, a masking peeling process. , A bending process, a joining process, a drawing process, a bottom member mounting process, a balance ring mounting process, a rotating tank mounting process, and the like. Hereinafter, each process is demonstrated in order.
- This press working process includes at least a cutting process, a hole forming process, and a protrusion forming process.
- 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
- holes 105a are 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.
- 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.
- a plate material Sa cut into a predetermined size and having holes 105a and protrusions 105b is obtained.
- the order of performing the cutting step, the hole forming step, and the protrusion forming step can be changed as appropriate.
- the hole forming step may be performed after the protrusion forming 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).
- a predetermined part of the surface of the plate material Sa that forms the outer surface of the side portion of the rotating tub 104 is covered with a masking material (not shown).
- a masking material for example, as shown in FIG. 5, in this case, the joint portions Ra and Rb set at both ends in the longitudinal direction of the plate material Sa and the both ends in the short direction perpendicular to the longitudinal direction of the plate material Sa are set. Molding portions Rc and Rd are covered with a masking material. In FIG. 5, the holes 105a and the protrusions 105b are not shown.
- the width dimension Wa of the joint portion Ra and the width dimension Wb of the joint portion Rb may be set to dimensions slightly larger than 2 to 4 mm, which is a general weld width dimension, for example, in the longitudinal direction of the plate material Sa. It is preferable to provide a width of about 5 mm from the end.
- the width dimensions Wa and Wb may be set with the same dimension or may be set with different dimensions.
- a masking material it is preferable to use a material with heat resistance as high as possible.
- the part covered with the masking material in the plate material Sa is made too large, there is a possibility that the area to which the antifouling coating is applied on the outer surface of the side portion of the rotating tub 104 becomes unnecessarily narrow. Therefore, in this masking step, it is preferable to pay attention so that the area covered with the masking material does not become larger than necessary.
- the area covered with the masking material may be appropriately adjusted so that the region above the lowest level water level L is coated with antifouling as much as possible. .
- a hydrophilic material is sprayed on the surface of the plate material Sa that forms the outer surface of the side portion of the rotating tub 104.
- the hydrophilic material is coated on the surface of the plate material Sa that forms the outer surface of the side portion of the rotary tank 104.
- the hydrophilic material is coated on a region of the plate material Sa excluding a portion covered with the masking material. Therefore, in this case, for example, the hydrophilic materials are not painted on the joint portions Ra and Rb and the molding portions Rc and Rd covered with the masking material in the plate material Sa shown in FIG.
- the sprayed hydrophilic material is easily adapted to the surface of the plate material Sa.
- the hydrophilic material painted on the plate material Sa is baked at a predetermined temperature.
- 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. .
- the plate material Sa provided with the antifouling coating 300 is bent into a cylindrical shape by a bending machine 501.
- plate material Sa is performed prior to this bending process.
- 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.
- the time required for bending the plate material Sa by the bending machine 501 can be carried out in about 2 to 3 seconds, for example, but the time can be changed as appropriate.
- 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.
- joining of both ends in the longitudinal direction of the plate material Sa is performed by welding.
- the cylindrical intermediate body 104S which is the original form of the rotation tank 104 is obtained.
- the welding of the plate material Sa is advanced in the direction from the upper part to the lower part in the rotary tank 104, that is, in the direction of the arrow Ya.
- the welding of the plate material Sa may proceed in the direction from the lower part to the upper part in the rotary tank 104, that is, in the direction of the arrow Yb.
- drawing is performed in order to deform a part of the cylindrical plate material Sa, that is, the intermediate body 104S obtained by the joining process. That is, for example, as shown in FIG. 9, the shape of the molded parts Rc, Rd is narrowed inward by pressing a roller or the like (not shown) from the outer surface side to a portion of the intermediate body 104S consisting of the molded 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. 9, the antifouling coating 300 is not shown.
- 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. 10, 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
- 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. 11, the balance ring 106 is fitted inside the balance ring attachment 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.
- 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.
- illustration of the hole 105a and the protrusion part 105b is abbreviate
- 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.
- 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.
- plate material Sa is performed prior to this bending process.
- 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.
- a hydrophilic material is sprayed on the outer surface of the side portion of the intermediate 216S, that is, the surface forming the outer surface of the side portion of the drum 216 in this case. That is, for example, as shown in FIG. 14, 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.
- the hydrophilic material is also sprayed onto the joined part or screwed part of the intermediate 216S.
- a predetermined portion of the outer surface of the side portion of the intermediate 216S may be covered with a masking material.
- the part covered with the masking material can be implemented by appropriately changing, for example, a part to be joined of the plate material Sa. Thereby, the structure which does not give antifouling coating to the part etc. which are joined, for example among board
- 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.
- 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.
- illustration of the hole 218 etc. is abbreviate
- 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.
- 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.
- 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.
- 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.
- the antifouling coating 300 is provided on almost the entire outer surface of the side portion of the rotating tubs 104 and 216. Therefore, almost 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.
- 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 the 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.
- the antifouling coating 300 has a 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 ⁇ m 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 ⁇ m or less, and an extremely smooth antifouling coating 300 is realized.
- 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.
- the water channel 119 provided with the disinfectant unit 120 is provided opposite to the joint portion of the rotating tub 104, that is, the portion where the antifouling coating 300 is not applied. Therefore, the sanitary effect by the disinfectant can be given to the site where it is difficult to obtain the antifouling effect by the antifouling coating 300.
- the antifouling coating 300 is provided in a region higher than the lowest level water level L among the water levels that can be set in the washing machine 100. Therefore, in most operations performed by the washing machine 100, water can be brought into contact with or reach the antifouling coating 300, and the antifouling effect of the antifouling coating 300 can be effectively exhibited.
- the manufacturing method of the washing machine according to the present embodiment it is possible to provide the washing machines 100 and 200 provided with the antifouling coating having a stable quality.
- 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.
- 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.
- 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.
- 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.
- the antifouling coating 300 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.
- the antifouling coating 300 may be colored. That is, as the hydrophilic material that forms the antifouling coating 300, a material that retains color after spraying onto the substrate and after baking 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.
- 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.
- This embodiment is also an embodiment in which the antifouling coating 300 is not applied to the portion to be joined on the surface forming the outer surface of the side portion of the rotating tub 104 in the plate material Sa. That is, for example, as shown in FIG. 15, in the masking process, the joint portions Ra and Rb set at both ends in the longitudinal direction of the plate material Sa are covered with the masking material, and the short side direction orthogonal to the longitudinal direction of the plate material Sa is used. The molding parts Rc and Rd set at both ends are not covered with a masking material.
- the antifouling coating 300 can be applied to almost the entire outer surface of the side portion of the rotating tank 104. 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 tank 104.
- the region where the antifouling coating is applied on the outer surface of the side portion of the rotating tank can be appropriately adjusted.
- the antifouling coating 300 is not provided on the entire outer surface of the side portion of the drum 216 or the entire outer surface of the side portion of the rotating tub 104, but a part of the outer surface of the side portion of the drum 216 or the side portion of the rotating tub 104 is provided.
- An antifouling coating 300 is provided on a part of the outer surface.
- the washing operation is performed at a portion lower than the set water level L indicated by the one-dot chain line.
- the water stored in the water tank 208 or the water tank 102 comes into contact with the water or during the rinsing operation. Therefore, a portion lower than the set water level L on the outer surface of the drum 216 side or the outer surface of the rotating tub 104 can be kept relatively clean without providing the antifouling coating 300.
- the portion of the outer surface of the drum 216 side or the outer surface of the rotating tub 104 that is higher than the set water level L is in contact with water stored in the water tank 208 or the water tank 102 during the washing operation or the rinsing operation. Therefore, dirt is likely to remain.
- the antifouling coating 300 is provided on a portion higher than the set water level L on the outer surface of the drum 216 side or the outer surface of the rotating tank 104 side. .
- the antifouling function can be used effectively.
- the amount of hydrophilic material used can be reduced. Since the set water level L can be changed, the region where the antifouling coating 300 is formed may be appropriately adjusted according to the assumed water level. At this time, the region where the antifouling coating 300 is formed may be set wider, for example, including the lowest water level that can be set in the washing machines 100, 200, or to the extent that the water level may vary.
- the antifouling coating 300 is not provided on the entire outer surface of the side portion of the drum 216 or the entire outer surface of the side portion of the rotating tub 104, but a part of the outer surface of the side portion of the drum 216 or the side portion of the rotating tub 104.
- An antifouling coating 300 is provided on a part of the outer surface.
- the portion lower than the set water level L on the outer surface of the drum 216 side or the outer surface of the rotary tank 104 is a portion that is easily contacted with water and kept relatively clean, but is completely It does not mean that there is no stain on the surface.
- the portion of the outer surface of the drum 216 side or the outer surface of the rotating tub 104 that is lower than the set water level L is a portion that comes into contact with water during the washing operation or the rinsing operation. Therefore, if dirt remains in this portion, the dirt may be deteriorated due to a change with time or the like, and the deteriorated dirt may be transferred to the laundry during the washing operation or the rinsing operation.
- the antifouling coating 300 is provided on the outer surface of the drum 216 side or the outer surface of the rotating tub 104 side lower than the set water level L. . Accordingly, the hydrophilic performance, which is an example of the antifouling function, is concentrated on the portion of the outer surface of the drum 216 side or the outer surface of the side of the rotating tub 104 that may remain relatively clean but may remain dirty. In the washing operation or the rinsing operation, it is possible to prevent the deteriorated dirt from being transferred to the laundry. In addition, the amount of hydrophilic material used can be reduced.
- the region where the antifouling coating 300 is formed may be appropriately adjusted according to the assumed water level. At this time, the region where the antifouling coating 300 is formed may be set wider, for example, including the lowest water level that can be set in the washing machines 100, 200, or to the extent that the water level may vary.
- the present embodiment is not limited to the above-described embodiments, 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.
- 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 of the rotating tank, not on the entire outer surface of the side of the rotating tank. 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 dewatering shaft 113a and the washing shaft 113b can be performed at an appropriate timing, for example, before or after the dehydration 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
- the washing machine 200 may further include an antifouling coating 300 on the outer surface of the bottom that forms the back surface of the drum 216.
- the antifouling coating 300 may be provided on the entire outer surface of the back surface of the drum 216, or the antifouling coating 300 may be provided on a part of the outer surface of the back surface of the drum 216.
- the bottom member 104b constituting the bottom portion is made of a metal made of, for example, stainless steel, the outer surface of the bottom portion formed by the metal bottom member 104b is also protected.
- the antifouling coating 300 may be provided on the entire outer surface of the metal bottom, or the antifouling coating 300 may be provided on a part of the outer surface of the metal bottom.
- the washing machine 200 may further include the antifouling coating 300 on the reinforcing member 217 that reinforces the bottom portion that constitutes the back surface portion of the drum 216.
- the antifouling coating 300 may be provided on the entire surface of the reinforcing member 217, or the antifouling coating 300 may be provided on a part of the surface of the reinforcing member 217.
- the washing machine 100 may further include a stainproof coating 300 on the reinforcing member 104 c that reinforces the bottom of the rotating tub 104.
- the antifouling coating 300 may be provided on the entire surface of the reinforcing member 104c, or the antifouling coating 300 may be provided on a part of the surface of the reinforcing member 104c. Further, the antifouling coating 300 may be provided on both the upper surface and the lower surface of the reinforcing member 104c, or the antifouling coating 300 may be provided on either the upper surface or the lower surface of the reinforcing member 104c.
- the washing machines 100 and 200 may be configured not to include the hydrophilic performance film 300 on the end surfaces 105t and 218t constituting the inner peripheral surfaces of the holes 105a and 218.
- the washing machines 100 and 200 may be configured to include a hydrophilic performance film 300 on the end surfaces 105t and 218t of the holes 105a and 218.
- the washing machine according to the present embodiment described above is a washing machine in which a metal plate is bent into a cylindrical shape to form a side portion of a rotating tub that is rotatably provided in a water tub. It is manufactured by carrying out a coating process for applying an antifouling coating having an antifouling function to the surface forming the outer surface of the side of the rotating tank, and the antifouling coating is applied to the outer surface of the side of the rotating tank. ing.
- the washing machine manufacturing method is a method for manufacturing a washing machine in which a metal plate is bent into a cylindrical shape to form a side portion of a rotating tub that is rotatably provided in a water tub.
- the antifouling coating is applied to the outer surface of the side of the rotating tank by performing a coating step of applying an antifouling coating having an antifouling function to the surface of the plate material that forms the outer surface of the side of the rotating tank.
- 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.
- the washing machine by this embodiment, it manufactures by implementing the bending process which bends a board
- the washing machine according to the present embodiment is a washing machine manufactured by performing a joining process of joining both ends of the plate material after the bending process, and in the coating process, both ends to be joined of the plate material. No antifouling coating is applied to the part.
- the washing machine is a washing machine manufactured by performing a processing step of processing a cylindrical plate material after a bending step of bending the plate material into a cylindrical shape. Antifouling coating is not applied to the applied part. Specifically, in the washing machine, a portion of the plate material to which drawing processing is applied is not subjected to the antifouling coating. Moreover, antifouling coating is not given to the part to which a balance ring is attached among board
- antifouling coating is not given to the part to which a bottom member is attached among board
- the plate materials are joined by TIG welding, if the part to be joined or its periphery is coated, welding may not be successful.
- the antifouling coating is not applied to both ends of the plate material to be joined in the coating process. Therefore, even when the plate materials are joined by TIG welding, the plate materials can be favorably welded.
- the baking process of baking the coating material attached to the plate material in the coating process is possible to manufacture by implementing. Thereby, after forming a strong antifouling coating, a board
- 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
- the washing machine which concerns on this embodiment, it is possible to manufacture by performing the baking process which bakes the coating material adhering to the board
- washing machine which concerns on this embodiment it can manufacture by implementing a coating process after the hole formation process which forms a hole in a board
- the washing machine which concerns on this embodiment, it is possible to manufacture by implementing a coating process after a diameter expansion process.
- a coating process after a diameter expansion process.
- 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 washing machine according to the present embodiment can be manufactured by performing a baking step of baking the coating material attached to the plate material in the coating step after the diameter expanding step and the coating step. That is, by forming a strong antifouling coating after a process that requires an excessive load, damage to the antifouling coating can be suppressed.
- the washing machine in the coating process, when the antifouling coating is applied to a portion of the plate material that forms a region higher than the lowest water level that can be set on the outer surface of the side portion of the rotating tub. Good. Thereby, in most operations performed by the washing machine, water can be brought into contact with or reach the antifouling coating, and the antifouling effect by the antifouling coating can be effectively exhibited.
- 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.
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Abstract
Description
例えば図1に示す洗濯機100は、回転槽の回転中心軸が垂直方向に延びるいわゆる縦軸型の洗濯機であり、その外郭を構成する外箱101の内部には、上面が開放した有底円筒状の水槽102が弾性吊持機構103によって弾性的に支持されている。この水槽102の内部には、上面が開放した有底円筒状の回転槽104が回転可能に設けられている。
(1)縦軸型洗濯機100の製造方法の一例
洗濯機100の製造方法は、以下に例示するプレス加工工程、洗浄工程、水切り/乾燥工程、マスキング工程、コーティング工程、焼付工程、マスキング剥がし工程、曲げ工程、接合工程、絞り加工工程、底部材の取り付け工程、バランスリングの取り付け工程、回転槽の取り付け工程などを含む。以下、各工程を順に説明する。
このプレス加工工程は、少なくとも、切断工程、孔形成工程、突起形成工程を含む。例えば図3に示すように、切断工程では、例えばステンレスなどからなる金属製の母材Sから、回転槽104を形成するための基材となる板材Saが得られる。即ち、金属製の母材Sは、送り機401によって順次送られ、そして、切断機402によるプレス加工よって順次切断される。これにより、回転槽104を形成するために所定の大きさに切断された板材Saが得られる。
この洗浄工程では、プレス加工工程によって得られた板材Saを洗浄する。なお、板材Saに保護シートが貼り付けられている場合には、この洗浄工程に先立ち、当該保護シートを板材Saから剥がす剥がし工程が行われる。この洗浄工程においては、板材Saがステンレス製であることから、例えばPH14といった強アルカリ性の脱脂剤を用いて板材Saの脱脂を行うことが可能である。よって、強アルカリ性の脱脂剤による洗浄効果により、板材Saの表面から殆どあるいは確実に油脂成分を除去することができる。
この水切り/乾燥工程では、板材Saに残っている脱脂剤が例えば拭き取りによって除去される。さらに、図示しない乾燥機によって板材Saの乾燥が行われる。
このマスキング工程では、板材Saのうち回転槽104の側部の外面を形成する面における所定部位を、図示しないマスキング材によって覆う。例えば図5に示すように、この場合、板材Saの長手方向の両端部に設定された接合部Ra,Rb、および、板材Saのうち長手方向と直行する短手方向の両端部に設定された成形加工部Rc,Rdがマスキング材によって覆われる。なお、図5では、孔105aや突起105bの図示を省略している。
このコーティング工程では、板材Saのうち回転槽104の側部の外面を形成する面に、この場合、親水性材料を吹き付ける。これにより、板材Saのうち回転槽104の側部の外面を形成する面に親水性材料が塗装される。この場合、板材Saのうちマスキング材によって覆われている部分を除く領域に親水性材料が塗装される。よって、この場合、例えば図5に示す板材Saのうちマスキング材で覆われている接合部Ra,Rbおよび成形加工部Rc,Rdには親水性材料が塗装されない。また、上述の洗浄工程において十分に油脂成分が除去されていれば、吹き付けた親水性材料が板材Saの表面に対して馴染みやすくなる。なお、上述した孔形成工程あるいは突起形成工程は、このコーティング工程の後に実施してもよい。
この焼付工程では、板材Saに塗装された親水性材料を所定温度で焼き付ける。なお、親水性材料の焼き付け温度は、一般的に有機物が分解する温度であると考えられている250℃よりも高い温度で設定することが好ましく、例えば300℃、500℃といった温度で設定するとよい。このような高温で親水性材料を焼き付けることにより、当該親水性材料に含まれる有機物を殆どあるいは完全に分解することができ、殆どあるいは完全に無機化された防汚コーティング300を形成することができる。
このマスキング剥がし工程では、板材Saに貼り付けられているマスキング材を剥がす。これにより、マスキング材によって覆われた部分を除く部分に防汚コーティング300が施された板材Saが得られる。なお、得られた板材Saを台車やトラックなどに積んで輸送する場合には、板材Saの表面に保護シートを貼り付けるようにするとよい。
この曲げ工程では、例えば図6に示すように、防汚コーティング300が施された板材Saを曲げ加工機501によって円筒状に曲げる。なお、板材Saに保護シートが貼り付けられている場合には、この曲げ工程に先立ち、当該保護シートを板材Saから剥がす剥がし工程が行われる。この場合、曲げ加工機501は、板材Saの両面、つまり親水性材料が塗装された面および塗装されていない面の双方を挟むようにして送ることにより、当該板材Saを円筒状に曲げる構成である。なお、曲げ加工機501による板材Saの曲げ加工に要する時間は、例えば2~3秒ほどで実施可能であるが、その時間は、適宜変更して実施することができる。また、上述の焼付工程は、この曲げ工程の後に実施してもよい。
この接合工程では、例えば図7に示すように、曲げ工程によってほぼ円筒状に曲げられた板材Saの長手方向の両端部、つまり接合部Ra,Rbの端部同士を接合する。この場合、板材Saの長手方向の両端部の接合は、溶接により行われる。これにより、回転槽104の原形である円筒状の中間体104Sが得られる。また、この場合、板材Saの溶接は、回転槽104において上側となる部分から下側となる部分に向かう方向、つまり矢印Ya方向に進められる。しかし、板材Saの溶接は、回転槽104において下側となる部分から上側となる部分に向かう方向、つまり矢印Yb方向に進めてもよい。また、例えば図8に示すように、板材Saの長手方向の両端部を、かしめることにより接合するようにしてもよい。
この絞り加工工程では、円筒状となった板材Sa、つまり接合工程により得られた中間体104Sの一部を変形させるために絞り加工を施す。即ち、例えば図9に示すように、中間体104Sのうち成形加工部Rc,Rdからなる部分に図示しないローラなどを外面側から押し付けることにより、成形加工部Rc,Rdの形状を内側に絞る。これにより、中間体104Sの上部、つまり回転槽104において上側となる部分には、バランスリング取付部104Saが形成され、中間体104Sの下部、つまり回転槽104において下側となる部分には、底部材取付部104Sbが形成される。なお、図9においては、防汚コーティング300の図示を省略している。
この取り付け工程では、中間体104Sの下部側に設けられた底部材取付部104Sbに底部材104bを取り付ける。即ち、例えば図10に示すように、底部材取付部104Sbの内側に底部材104bを嵌め込む。そして、底部材取付部104Sbの下端を内側に折り曲げて、底部材104bに係止させる。これにより、底部材104bが、底部材取付部104Sb内に取り付けられ固定される。
この取り付け工程では、中間体104Sの上部側に設けられたバランスリング取付部104Saにバランスリング106を取り付ける。即ち、例えば図11に示すように、バランスリング取付部104Saの内側にバランスリング106を嵌め込む。そして、バランスリング取付部104Saの外側からねじ106aをねじ込む。これにより、バランスリング106が、バランスリング取付部104Sa内に取り付けられ固定される。
中間体104Sに底部材104bおよびバランスリング106が取り付けられることにより、回転槽104が製造される。そして、その回転槽104は、洗濯機100の水槽102内に回転可能に取り付けられる。なお、図面では、孔105aや突部105bの図示を省略している。
洗濯機200の製造方法は、以下に例示するプレス加工工程、洗浄工程、水切り/乾燥工程、曲げ工程、接合工程、径拡大工程、背面板の取り付け工程、コーティング工程、焼付工程、バランスリングの取り付け工程、回転槽の取り付け工程などを含む。以下、各工程を順に説明する。
プレス加工工程、洗浄工程、水切り/乾燥工程は、それぞれ、上述したプレス加工工程、洗浄工程、水切り/乾燥工程と同様であるので説明を省略する。
この曲げ工程では、板材Saを曲げ加工機501によって円筒状に曲げる。即ち、この場合、防汚コーティング300が施されていない板材Saを円筒状に曲げる。なお、板材Saに保護シートが貼り付けられている場合には、この曲げ工程に先立ち、当該保護シートを板材Saから剥がす剥がし工程が行われる。
接合工程は、上述した接合工程と同様であるので説明を省略する。
≪径拡大工程≫
この径拡大工程(エキスパンド工程)では、円筒状となった板材Sa、つまり接合工程により得られた中間体216Sの径寸法を拡大する。即ち、例えば図12(a)に矢印Eで示すように、中間体216Sの内側から、図示しない拡開機により当該中間体216Sの特に中間部分を外側に押し拡げる。これにより、例えば図12(b)に示すように、中間体216Sの特に中間部分の径寸法を若干拡大することができる。なお、図面では、説明の便宜のため、径寸法の拡大量を実際よりも誇張して示している。
この取り付け工程では、例えば図13に示すように、中間体216Sに背面板216Hを取り付ける。即ち、中間体216Sの一端部内に例えばステンレスなどからなる金属製の背面板216Hを嵌め込む。そして、中間体216Sの外側から図示しないねじをねじ込む。これにより、背面板216Hが中間体216Sの一端部内に取り付けられ固定される。なお、この背面板216Hは、ドラム216の背面を構成するものであり、洗濯機200においては、モータ210の回転軸213や補強部材217などが取り付けられる。
このコーティング工程では、中間体216Sの側部の外面、つまりドラム216の側部の外面を形成する面に、この場合、親水性材料を吹き付ける。即ち、例えば図14に示すように、背面板216Hが取り付けられた中間体216Sを、例えば、背面板216Hが取り付けられた側を上にして回転テーブル601に載置する。そして、回転テーブル601によって中間体216Sを回転させながら、当該中間体216Sの外面に親水性材料を吹き付ける。これにより、ドラム216の側部の外面を形成する面に親水性材料が塗装される。この場合、中間体216Sのうち接合された部分やねじ止めされた部分にも親水性材料が吹き付けられる。なお、このコーティング工程に先立ち、中間体216Sの側部の外面のうちの所定部位をマスキング材によって覆うようにしてもよい。この場合、マスキング材で覆う部分は、例えば板材Saのうち接合される部分など、適宜変更して実施することができる。これにより、例えば板材Saのうち接合される部分などには防汚コーティングを施さない構成を実現することができる。
焼付工程は、上述した焼付工程と同様であるので説明を省略する。
≪バランスリングの取り付け工程≫
この取り付け工程では、中間体216Sにバランスリング222を取り付ける。即ち、中間体216Sのうち背面板216Hが取り付けられた側とは反対側の端部にバランスリング222を嵌め込む。そして、中間体216Sの外側から図示しないねじをねじ込む。これにより、バランスリング222が、中間体216Sに取り付けられ固定される。
中間体216Sにバランスリング222が取り付けられることにより、ドラム216が製造される。そして、そのドラム216は、洗濯機200の水槽208内に回転可能に取り付けられる。なお、図面では、孔218などの図示を省略している。
また、洗濯機100,200によれば、防汚コーティング300による防錆効果も期待することができる。
本実施形態も、板材Saのうち回転槽104の側部の外面を形成する面において、接合される部分には防汚コーティング300を施さないようにした実施形態である。即ち、例えば図15に示すように、マスキング工程では、板材Saの長手方向の両端部に設定された接合部Ra,Rbをマスキング材によって覆い、板材Saのうち長手方向と直行する短手方向の両端部に設定された成形加工部Rc,Rdはマスキング材によって覆わないようにする。
本実施形態は、ドラム216の側部の外面全体あるいは回転槽104の側部の外面全体に防汚コーティング300を設けるのではなく、ドラム216側部の外面の一部あるいは回転槽104側部の外面の一部に防汚コーティング300を設けたものである。
本実施形態も、ドラム216の側部の外面全体あるいは回転槽104の側部の外面全体に防汚コーティング300を設けるのではなく、ドラム216側部の外面の一部あるいは回転槽104側部の外面の一部に防汚コーティング300を設けたものである。
本実施形態は、上述した各実施形態に限定されるものではなく、例えば以下のように拡張または変形することができる。
また、例えば図21に示すように、洗濯機200は、さらに、ドラム216の背面部を構成する底部の外面にも防汚コーティング300を備える構成としてもよい。この場合、ドラム216の背面部の外面全体に防汚コーティング300を設けてもよいし、ドラム216の背面部の外面の一部に防汚コーティング300を設けてもよい。また、図示はしないが、洗濯機100は、底部を構成する底部材104bを例えばステンレスなどからなる金属で構成する場合には、その金属製の底部材104bにより形成される底部の外面にも防汚コーティング300を備える構成としてもよい。この場合、金属製の底部の外面全体に防汚コーティング300を設けてもよいし、金属製の底部の外面の一部に防汚コーティング300を設けてもよい。
以上に説明した本実施形態に係る洗濯機は、金属製の板材を円筒状に曲げることにより、水槽内に回転可能に設けられる回転槽の側部を形成した洗濯機であって、前記板材のうち前記回転槽の側部の外面を形成する面に、防汚機能を有する防汚コーティングを施すコーティング工程を実施することにより製造され、前記回転槽の側部の外面に防汚コーティングが施されている。
なお、本実施形態は、例として提示したものであり、発明の範囲を限定することは意図していない。これら新規な実施形態は、その他の様々な形態で実施されることが可能であり、発明の要旨を逸脱しない範囲で、種々の省略、置き換え、変更を行うことができる。本実施形態およびその変形は、発明の範囲および要旨に含まれるとともに、請求の範囲に記載された発明とその均等の範囲に含まれる。
Claims (48)
- 金属製の板材を円筒状に曲げることにより、水槽内に設けられる回転槽の側部を形成した洗濯機であって、
前記板材のうち前記回転槽の側部の外面を形成する面に、防汚機能を有する防汚コーティングを施すコーティング工程を実施することにより製造され、前記回転槽の側部の外面に防汚コーティングが施されている洗濯機。 - 前記コーティング工程の後に、前記板材を円筒状に曲げる曲げ工程を実施することにより製造される請求項1に記載の洗濯機。
- 前記曲げ工程の後に、前記板材の両端部を接合する接合工程を実施することにより製造される洗濯機であって、
前記コーティング工程では、前記板材のうち少なくとも両端部を除く領域に前記防汚コーティングを施す請求項2に記載の洗濯機。 - 前記コーティング工程では、前記板材のうち接合される部分には前記防汚コーティングを施さない請求項1から3の何れか1項に記載の洗濯機。
- 前記板材を円筒状に曲げる曲げ工程の後に、円筒状となった前記板材に加工を施す加工工程を実施することにより製造される洗濯機であって、
前記コーティング工程では、前記板材のうち前記加工工程により加工が施される部分には前記防汚コーティングを施さない請求項1から4の何れか1項に記載の洗濯機。 - 前記加工工程において、円筒状となった前記板材の一部を絞る絞り加工を施すことにより製造される洗濯機であって、
前記コーティング工程では、前記板材のうち絞り加工が施される部分には前記防汚コーティングを施さない請求項5に記載の洗濯機。 - 前記加工工程において、円筒状となった前記板材にバランスリングを取り付けることにより製造される洗濯機であって、
前記コーティング工程では、前記板材のうち前記バランスリングが取り付けられる部分には前記防汚コーティングを施さない請求項5または6に記載の洗濯機。 - 前記加工工程において、円筒状となった前記板材に前記回転槽の底部を形成する底部材を取り付けることにより製造される洗濯機であって、
前記コーティング工程では、前記板材のうち前記底部材が取り付けられる部分には前記防汚コーティングを施さない請求項5から7の何れか1項に記載の洗濯機。 - 前記コーティング工程の後であって、且つ、前記板材を円筒状に曲げる曲げ工程の前に、当該コーティング工程において前記板材に付着されたコーティング材料を焼き付ける焼付工程を実施することにより製造される請求項1から8の何れか1項に記載の洗濯機。
- 前記板材を円筒状に曲げる曲げ工程の後に、当該コーティング工程において前記板材に付着されたコーティング材料を焼き付ける焼付工程を実施することにより製造される請求項1から9の何れか1項に記載の洗濯機。
- 前記板材を円筒状に曲げる曲げ工程の後に、前記コーティング工程を実施することにより製造される請求項1に記載の洗濯機。
- 前記曲げ工程の後であって、且つ、前記コーティング工程の前に、前記板材の両端部を接合する接合工程を実施することにより製造される請求項11に記載の洗濯機。
- 前記コーティング工程では、前記板材のうち接合される部分には前記防汚コーティングを施さない請求項1,11,12の何れか1項に記載の洗濯機。
- 前記コーティング工程の後に、当該コーティング工程において前記板材に付着されたコーティング材料を焼き付ける焼付工程を実施することにより製造される請求項1,11,12,13の何れか1項に記載の洗濯機。
- 前記板材に孔を形成する孔形成工程の後に、前記コーティング工程を実施することにより製造される請求項1から14の何れか1項に記載の洗濯機。
- 前記板材に突起を形成する突起形成工程の後に、前記コーティング工程を実施することにより製造される請求項1から15の何れか1項に記載の洗濯機。
- 前記コーティング工程の後に、前記板材に突起を形成する突起形成工程を実施することにより製造される請求項1から15の何れか1項に記載の洗濯機。
- 前記板材を円筒状に曲げる曲げ工程、前記板材を接合する接合工程の後に、円筒状となった前記板材の径を拡大する径拡大工程を実施することにより製造される請求項1から17の何れか1項に記載の洗濯機。
- 前記径拡大工程の後に、前記コーティング工程を実施することにより製造される請求項18に記載の洗濯機。
- 前記径拡大工程および前記コーティング工程の後に、前記コーティング工程において前記板材に付着されたコーティング材料を焼き付ける焼付工程を実施することにより製造される請求項19に記載の洗濯機。
- 前記コーティング工程では、前記板材のうち、前記回転槽の側部の外面において設定可能な最低水位よりも高くなる領域を形成する部分に前記防汚コーティングを施す請求項1から20の何れか1項に記載の洗濯機。
- 前記回転槽を回転させるための回転槽回転軸を備え、
前記回転槽回転軸のうち前記水槽内に突出する部分に、防汚機能を有する防汚コーティングが施されている請求項1から21の何れか1項に記載の洗濯機。 - 前記回転槽内に回転可能に設けられた撹拌体と、
前記撹拌体を回転させるための撹拌体回転軸と、を備え、
前記撹拌体回転軸のうち前記水槽内に突出する部分に、防汚機能を有する防汚コーティングが施されている請求項1から22の何れか1項に記載の洗濯機。 - 金属製の板材を円筒状に曲げることにより、水槽内に設けられる回転槽の側部を形成した洗濯機を製造する方法であって、
前記板材のうち前記回転槽の側部の外面を形成する面に、防汚機能を有する防汚コーティングを施すコーティング工程を実施することにより、前記回転槽の側部の外面に防汚コーティングが施されている洗濯機を製造する洗濯機の製造方法。 - 前記コーティング工程の後に、前記板材を円筒状に曲げる曲げ工程を実施する請求項24に記載の洗濯機の製造方法。
- 前記曲げ工程の後に、前記板材の両端部を接合する接合工程を実施する洗濯機の製造方法であって、
前記コーティング工程では、前記板材のうち少なくとも両端部を除く領域に前記防汚コーティングを施す請求項25に記載の洗濯機の製造方法。 - 前記コーティング工程では、前記板材のうち接合される部分には前記防汚コーティングを施さない請求項24から26の何れか1項に記載の洗濯機の製造方法。
- 前記板材を円筒状に曲げる曲げ工程の後に、円筒状となった前記板材に加工を施す加工工程を実施する洗濯機の製造方法であって、
前記コーティング工程では、前記板材のうち前記加工工程により加工が施される部分には前記防汚コーティングを施さない請求項24から27の何れか1項に記載の洗濯機の製造方法。 - 前記加工工程において、円筒状となった前記板材の一部を絞る絞り加工を施す洗濯機の製造方法であって、
前記コーティング工程では、前記板材のうち絞り加工が施される部分には前記防汚コーティングを施さない請求項28に記載の洗濯機の製造方法。 - 前記加工工程において、円筒状となった前記板材にバランスリングを取り付ける洗濯機の製造方法であって、
前記コーティング工程では、前記板材のうち前記バランスリングが取り付けられる部分には前記防汚コーティングを施さない請求項28または29に記載の洗濯機の製造方法。 - 前記加工工程において、円筒状となった前記板材に前記回転槽の底部を形成する底部材を取り付ける洗濯機の製造方法であって、
前記コーティング工程では、前記板材のうち前記底部材が取り付けられる部分には前記防汚コーティングを施さない請求項28から30の何れか1項に記載の洗濯機の製造方法。 - 前記コーティング工程の後であって、且つ、前記板材を円筒状に曲げる曲げ工程の前に、当該コーティング工程において前記板材に付着されたコーティング材料を焼き付ける焼付工程を実施する請求項24から31の何れか1項に記載の洗濯機の製造方法。
- 前記板材を円筒状に曲げる曲げ工程の後に、当該コーティング工程において前記板材に付着されたコーティング材料を焼き付ける焼付工程を実施する請求項24から32の何れか1項に記載の洗濯機の製造方法。
- 前記板材を円筒状に曲げる曲げ工程の後に、前記コーティング工程を実施する請求項24に記載の洗濯機の製造方法。
- 前記曲げ工程の後であって、且つ、前記コーティング工程の前に、前記板材の両端部を接合する接合工程を実施する請求項34に記載の洗濯機の製造方法。
- 前記コーティング工程では、前記板材のうち接合される部分には前記防汚コーティングを施さない請求項24,34,35の何れか1項に記載の洗濯機の製造方法。
- 前記コーティング工程の後に、当該コーティング工程において前記板材に付着されたコーティング材料を焼き付ける焼付工程を実施する請求項24,34,35,36の何れか1項に記載の洗濯機の製造方法。
- 前記板材に孔を形成する孔形成工程の後に、前記コーティング工程を実施する請求項24から37の何れか1項に記載の洗濯機の製造方法。
- 前記板材に突起を形成する突起形成工程の後に、前記コーティング工程を実施する請求項24から38の何れか1項に記載の洗濯機の製造方法。
- 前記コーティング工程の後に、前記板材に突起を形成する突起形成工程を実施する請求項24から38の何れか1項に記載の洗濯機の製造方法。
- 前記板材を円筒状に曲げる曲げ工程、前記板材を接合する接合工程の後に、円筒状となった前記板材の径を拡大する径拡大工程を実施する請求項24から40の何れか1項に記載の洗濯機の製造方法。
- 前記径拡大工程の後に、前記コーティング工程を実施する請求項41に記載の洗濯機の製造方法。
- 前記径拡大工程および前記コーティング工程の後に、前記コーティング工程において前記板材に付着されたコーティング材料を焼き付ける焼付工程を実施する請求項42に記載の洗濯機の製造方法。
- 前記コーティング工程では、前記板材のうち、前記回転槽の側部の外面において設定可能な最低水位よりも高くなる領域を形成する部分に前記防汚コーティングを施す請求項24から43の何れか1項に記載の洗濯機の製造方法。
- 前記回転槽を回転させるための回転槽回転軸のうち前記水槽内に突出する部分に、防汚機能を有する防汚コーティングを施す請求項24から44の何れか1項に記載の洗濯機の製造方法。
- 前記回転槽内に回転可能に設けられた撹拌体を回転させるための撹拌体回転軸のうち前記水槽内に突出する部分に、防汚機能を有する防汚コーティングを施す請求項24から45の何れか1項に記載の洗濯機の製造方法。
- 前記防汚コーティングは、常時、防汚機能を発揮するものである請求項1から23の何れか一項に記載の洗濯機。
- 前記コーティング工程により、前記防汚コーティングとして、常時、防汚機能を発揮する防汚コーティングを施す請求項24から46の何れか1項に記載の洗濯機の製造方法。
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KR1020157032985A KR20150145252A (ko) | 2013-06-21 | 2014-06-19 | 세탁기 및 세탁기의 제조방법 |
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JP2016154802A (ja) * | 2015-02-26 | 2016-09-01 | 株式会社東芝 | 洗濯機 |
FR3100296A1 (fr) * | 2019-09-02 | 2021-03-05 | Bronze Alu | Tambour de frein composite |
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CN105937140B (zh) * | 2016-06-16 | 2019-06-18 | 无锡小天鹅股份有限公司 | 洗衣机 |
CN105937149A (zh) * | 2016-06-30 | 2016-09-14 | 无锡小天鹅股份有限公司 | 可拎式小洗衣机 |
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KR20180043411A (ko) | 2018-04-27 |
TW201527619A (zh) | 2015-07-16 |
TWI568905B (zh) | 2017-02-01 |
MY172535A (en) | 2019-11-30 |
CN105339543B (zh) | 2018-10-16 |
CN105339543A (zh) | 2016-02-17 |
KR101991781B1 (ko) | 2019-06-21 |
KR20150145252A (ko) | 2015-12-29 |
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