U.S. patent application number 14/591394 was filed with the patent office on 2015-07-09 for refrigerator and manufacturing method thereof.
This patent application is currently assigned to Samsung Electronics Co., Ltd. The applicant listed for this patent is Samsung Electronics Co., Ltd.. Invention is credited to Heung Seob Choi, Jong Tak Lee, Man Yeob Lee, Do Soo Sung.
Application Number | 20150192352 14/591394 |
Document ID | / |
Family ID | 52282621 |
Filed Date | 2015-07-09 |
United States Patent
Application |
20150192352 |
Kind Code |
A1 |
Sung; Do Soo ; et
al. |
July 9, 2015 |
REFRIGERATOR AND MANUFACTURING METHOD THEREOF
Abstract
A door of a refrigerator includes a front plate formed of a
metallic material, a display unit having a display part disposed at
a rear surface of the front plate to brighten and darken and thus
to display operation information of the refrigerator, and a
plurality of through-holes formed in an area of the front plate
corresponding to the display part. The display unit is hidden in
the door, but a user may see the information displayed on the
display unit through the through-holes of the front plate.
Inventors: |
Sung; Do Soo; (Suwon-si,
KR) ; Lee; Jong Tak; (Suwon-si, KR) ; Choi;
Heung Seob; (Suwon-si, KR) ; Lee; Man Yeob;
(Suwon-si, KR) |
|
Applicant: |
Name |
City |
State |
Country |
Type |
Samsung Electronics Co., Ltd. |
Suwon-si |
|
KR |
|
|
Assignee: |
Samsung Electronics Co.,
Ltd
Suwon-si
KR
|
Family ID: |
52282621 |
Appl. No.: |
14/591394 |
Filed: |
January 7, 2015 |
Current U.S.
Class: |
62/125 ;
29/890.035 |
Current CPC
Class: |
Y10T 29/49359 20150115;
F25D 2500/02 20130101; F25D 23/028 20130101; F25D 29/005 20130101;
F25D 23/064 20130101; F25D 2400/36 20130101 |
International
Class: |
F25D 23/02 20060101
F25D023/02; F25D 29/00 20060101 F25D029/00 |
Foreign Application Data
Date |
Code |
Application Number |
Jan 7, 2014 |
KR |
10-2014-0001655 |
Claims
1. A refrigerator comprising: a main body; a storage chamber formed
in the main body; and a door configured to open and close the
storage chamber, wherein the door comprises: a front plate
configured to form a front surface and side surfaces of the door; a
rear plate coupled to a rear portion of the front plate; an upper
cap coupled to an upper portion of the front plate; a lower cap
coupled to a lower portion of the front plate; a foaming space
defined by the front plate, the rear plate, the upper cap, and the
lower cap; an insulation material foamed into the foaming space;
and a display unit including a display part having a desired shape
to be turned on and off, and disposed at a rear side of the front
plate, and a through-hole having a diameter larger than half of a
thickness of the front plate is formed in the front plate.
2. The refrigerator according to claim 1, wherein the display unit
comprises a printed circuit board on which a Light Emitting Diode
(LED) is mounted, a guide part configured to guide the light of the
LED, and a cover sheet attached to a front surface of the guide
part and having the display part.
3. The refrigerator according to claim 1, wherein the diameter of
the through-hole is 0.1 mm or more and 0.5 mm or less.
4. The refrigerator according to claim 1, wherein the thickness of
the front plate is 0.6 mm or less.
5. The refrigerator according to claim 1, wherein the front plate
comprises a half-cut portion formed by half-cutting, and a
through-hole portion in which the through-hole is formed.
6. The refrigerator according to claim 5, wherein, when the front
plate is half-cut, the diameter of the through hole is formed to be
larger than or the same as the half of the thickness of the front
plate.
7. The refrigerator according to claim 1, wherein the door further
comprises a supporting member configured to support the display
unit.
8. The refrigerator according to claim 1, wherein the door further
comprises a guide member configured to press the display unit to a
front side so that the display unit is in close contact with the
front plate.
9. The refrigerator according to claim 8, wherein the door further
comprises a sealing member provided between the front plate and the
supporting member to prevent an insulation foaming agent from
permeating the display unit.
10. The refrigerator according to claim 1, wherein the door further
comprises a filler member in the through-hole to prevent a foreign
substance from permeating the through-hole.
11. The refrigerator according to claim 10, wherein the filler
member has a viscosity of 2000 centipoise (cP) or more.
12. A method of manufacturing a refrigerator which comprises a main
body, a storage chamber, and a door configured to open and close
the storage chamber and having a front plate formed of a steel
plate, comprising: forming a through-hole having a diameter larger
than half of a thickness of the front plate in the front plate, and
filling a filler member in the through-hole to prevent a foreign
substance from permeating the through-hole.
13. The method of manufacturing the refrigerator according to claim
12, wherein the forming of the through-hole in the front plate
comprises half-cutting the front plate to form a half-cut portion
and a through-hole portion, and forming the through-hole having a
diameter larger than or the same as the half of the thickness of
the front plate in the through-hole portion.
14. The method of manufacturing the refrigerator according to claim
12, wherein the filler member has a viscosity of 2000 centipoise
(cP) or more.
15. The method of manufacturing the refrigerator according to claim
12, wherein the filling of the filler member in the through-hole
comprises attaching a protection vinyl on a front surface of the
front plate, and coating an inner portion of the through-hole with
the filler member through a rear surface of the front plate on
which the protection vinyl is not attached.
16. The method of manufacturing the refrigerator according to claim
15, wherein the protection vinyl is formed of a polyethylene
material.
17. A display apparatus for a refrigerator, the display apparatus
comprising: a printed circuit board comprising a Light Emitting
Diode (LED); a display part; a guide hole configured to guide the
light of the LED to the display part; and a front plate comprising
a pattern of through-holes; wherein each through-hole in the
pattern of through-holes has a diameter greater than or equal to
half of a thickness of the front plate, and the pattern of
through-holes has a location corresponding to the location of the
guide hole for the LED.
18. The display apparatus according to claim 17, wherein the front
plate forms a front portion of a door of the refrigerator.
19. The display apparatus according to claim 17, further
comprising: a filler member in each through-hole in the pattern of
through-holes.
Description
CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This application claims the priority benefit of Korean
Patent Application No. 10-2014-0001655, filed on Jan. 7, 2014 in
the Korean Intellectual Property Office, the disclosure of which is
incorporated herein by reference.
BACKGROUND
[0002] 1. Field
[0003] The following description relates to a refrigerator having a
display unit provided at a door.
[0004] 2. Description of the Related Art
[0005] In general, a refrigerator is a home appliance which
includes a storage chamber configured to store food and a cold air
supplying device configured to supply cold air to the storage
chamber, which keeps food fresh. The storage chamber is opened and
closed by a door, and a display unit configured to display
operation information of the refrigerator or to receive operation
commands of the refrigerator is provided at the door.
[0006] There is a refrigerator in which the display unit may be
hidden in the door in order to improve an exterior appearance
thereof. At this time, a front plate of the door is formed of a
tempered glass material or a transparent resin material, such that
the information displayed on the display unit may be viewed through
the front plate.
SUMMARY
[0007] Therefore, it is an aspect of the present disclosure to
provide a door of a refrigerator, which has a front plate thereof
formed of a steel plate and in which a display unit is hidden.
[0008] It is an aspect of the present disclosure to provide a door
of a refrigerator, in which information displayed on the display
unit may be normally viewed through through-holes formed in the
front plate, even when the refrigerator is viewed obliquely.
[0009] It is an aspect of the present disclosure to provide a
method of manufacturing a door of a refrigerator, which may prevent
generation of unfilled portions and bubbles when filling the
through-holes with a filler member.
[0010] Additional aspects of the disclosure will be set forth in
part in the description which follows and, in part, will be obvious
from the description, or may be learned by practice of the
disclosure.
[0011] In accordance with an aspect of the present disclosure, a
refrigerator includes a main body, a storage chamber formed in the
main body, and a door configured to open and close the storage
chamber, wherein the door includes a front plate configured to form
a front surface and side surfaces of the door, a rear plate coupled
to a rear portion of the front plate, an upper cap coupled to an
upper portion of the front plate, a lower cap coupled to a lower
portion of the front plate, a foaming space sealed by the front
plate, the rear plate, the upper cap, and the lower cap, an
insulation material foamed into the foaming space, and a display
unit including a display part having a desired shape to be turned
on and off, and disposed at a rear side of the front plate, and
through-holes having a diameter larger than a half of a thickness
of the front plate and a shape corresponding to a shape of the
display part of the display unit are formed in the front plate.
[0012] The display unit may include a printed circuit board on
which at least one LED emitting light is mounted, a guide part
configured to guide the light of the at least one LED, and a cover
sheet attached to a front surface of the guide part and having the
display part.
[0013] The diameter of each through-hole may be from approximately
0.1 mm to approximately 0.5 mm.
[0014] The thickness of the front plate may be approximately 0.6 mm
or less.
[0015] The front plate may include a half-cut portion formed by
half-cutting, and a through-hole portion in which the through-holes
are formed.
[0016] When the front plate is half-cut, the diameter of each
through hole may be formed to be larger than or the same as the
half of the thickness of the front plate.
[0017] The door may further include a supporting member configured
to support the display unit.
[0018] The door may further include a guide member configured to
press the display unit to a front side so that the display unit is
in close contact with the front plate.
[0019] The door may further include a sealing member provided
between the front plate and the supporting member to prevent an
insulation foaming agent from permeating the display unit.
[0020] The door may further include a filler member filled in the
through-holes to prevent foreign substances from permeating the
through-holes.
[0021] The filler member may have a viscosity of 2000 centipoise
(cP) or more.
[0022] In accordance with an aspect of the present disclosure, a
method of manufacturing a refrigerator which includes a main body,
a storage chamber, and a door configured to open and close the
storage chamber and having a front plate formed of a steel plate
includes forming through-holes having a diameter larger than a half
of a thickness of the front plate in the front plate, and filling a
filler member in the through-holes to prevent foreign substances
from permeating the through-holes.
[0023] The forming of the through-holes having the diameter larger
than the half of the thickness of the front plate in the front
plate may include half-cutting the front plate to form a half-cut
portion and a through-hole portion, and forming through-holes
having a diameter larger than or the same as the half of the
thickness of the front plate.
[0024] The filler member may have a viscosity of 2000 centipoise
(cP) or more.
[0025] The filling of the filler member in the through-holes may
include attaching a protection vinyl on a front surface of the
front plate, and coating inner portions of the through-holes with
the filler member through a rear surface of the front plate on
which the protection vinyl is not attached.
[0026] The protection vinyl may be formed of a polyethylene
material.
BRIEF DESCRIPTION OF THE DRAWINGS
[0027] These and/or other aspects of the disclosure will become
apparent and more readily appreciated from the following
description of the embodiments, taken in conjunction with the
accompanying drawings of which:
[0028] FIG. 1 is a view of an exterior of a refrigerator in
accordance with an embodiment of the present disclosure;
[0029] FIG. 2 is an exploded perspective view schematically
illustrating the refrigerator of FIG. 1;
[0030] FIG. 3 is a cross-sectional view illustrating the
refrigerator of FIG. 1;
[0031] FIG. 4 is a view illustrating a state in which a display
unit of the refrigerator of FIG. 1 is disassembled;
[0032] FIG. 5 is an enlarged view illustrating the vicinity of
through-holes of a front plate of the refrigerator of FIG. 1;
[0033] FIG. 6 is an enlarged view illustrating the vicinity of the
through-holes of the front plate in a state in which the display
unit of the refrigerator of FIG. 1 is turned off;
[0034] FIG. 7 is a cross-sectional view taken along a line B-B of
FIG. 5;
[0035] FIG. 8 is a view illustrating a state in which the
through-holes in FIG. 7 are filled with a filler member;
[0036] FIG. 9 is a view illustrating a state in which an error is
generated while the through-holes are coated with the filler member
in accordance with the embodiment of the present disclosure;
[0037] FIG. 10 is a view illustrating a state in which air is
removed from the through-holes of FIG. 9 using a vacuum
apparatus;
[0038] FIG. 11 is a flow chart illustrating a process of filling
the through-holes with the filler member in accordance with an
embodiment of the present disclosure;
[0039] FIG. 12 is a view illustrating a state in which the
through-holes are coated with the filler member in accordance with
the embodiment of the present disclosure;
[0040] FIG. 13 is a flow chart illustrating a process of filling
the through-holes with the filler member in accordance with an
embodiment of the present disclosure;
[0041] FIG. 14 is a view illustrating a relationship between a
thickness of the front plate of the refrigerator and a size of each
of the through-holes in accordance with the embodiment of the
present disclosure; and
[0042] FIG. 15 is a view illustrating the relationship between the
thickness of the front plate of the refrigerator and the size of
each of the through-holes when the front plate of the refrigerator
is half-cut in accordance with the embodiment of the present
disclosure.
DETAILED DESCRIPTION
[0043] Reference will now be made in detail to the embodiments of
the present disclosure, examples of which are illustrated in the
accompanying drawings.
[0044] FIG. 1 is a view of an exterior of a refrigerator in
accordance with an embodiment of the present disclosure.
[0045] Referring to FIG. 1, a refrigerator 1 includes a main body
10, storage chambers 11 and 12 provided in the main body 10, and a
cold air supplying device (not shown) configured to supply cold air
to the storage chamber.
[0046] The storage chambers 11, 12 may be partitioned into an upper
refrigerator chamber 11 and a lower freezer chamber 12. The
refrigerator chamber 11 may store food at a temperature of
approximately 0.degree. C. The refrigerator chamber 11 has a front
surface which is opened to put in or take out food. The opened
front surface may be opened and closed by a pair of doors 21 and 22
rotatably coupled to the main body 10. The pair of doors 21 and 22
may have handles 21a and 22a.
[0047] The freezer chamber 12 may store food at a sub-zero
temperature. The freezer chamber 12 has a front surface which is
opened to put in or take out food. The opened front surface may be
opened and closed by a door 31 disposed to be slidable forward and
backward. The door 31 may have a handle 31a.
[0048] A plurality of through-holes 51 configured to display
operation information of the refrigerator may be provided in one 21
of the doors 21 and 22. The through-holes 51 may at least partially
brighten or darken to display a specific image and thus may display
the operation information of the refrigerator. The configuration of
the through-holes 51 will be described below.
[0049] Meanwhile, as described above, the embodiment of the present
disclosure is an FDR type refrigerator. However, the spirit of the
present disclosure is not restricted by a type of the refrigerator,
and may be applied to all kinds of refrigerators.
[0050] FIG. 2 is an exploded perspective view schematically
illustrating the refrigerator of FIG. 1. FIG. 3 is a
cross-sectional view illustrating the refrigerator of FIG. 1.
[0051] Referring to FIGS. 2 and 3, the door 21 includes a front
plate 50 configured to form a front surface and both sides surfaces
of the door 21, a rear plate 70 configured to be coupled to a rear
surface of the front plate 50 and to form a rear surface of the
door 21, and an upper cap 60 and a lower cap 90 configured to seal
upper and lower ends of an internal space defined between the front
plate 50 and the rear plate 70.
[0052] The handle 21a may be provided at the front plate 50. The
front plate 50 may be formed of a metallic material such as steel,
aluminum, an alloy, PCM, and VCM, for example. The front plate 50
may be formed by bending a single plate to form the front and both
side surfaces of the door 21.
[0053] The front plate 50 may provide high strength and a luxurious
feel due to the nature of the metallic material, compared to a
tempered glass plate or a resin plate. The front plate 50 may have
an enhanced appearance through a characteristic surface treatment
of the metallic material.
[0054] That is, a hair line process, a mirror polishing process, a
bead blast process or the like may be performed on a surface of the
front plate 50. At this time, only one of the processes may be
performed on the front plate 50.
[0055] Alternatively, all of the processes may be performed on the
front plate 50. That is, the front plate 50 may have all of hair
line patterns, gloss, and beads. At this time, the mirror polishing
process, the hair line process, and the bead blast process may be
performed in turn.
[0056] The rear plate 70 may be vacuum-molded from a resin
material. The rear plate 70 may have a dike 71 protruding rearward
so that a door pocket may be installed.
[0057] The upper cap 60 and the lower cap 90 may be
injection-molded from the resin material. The front plate 50, the
rear plate 70, the upper cap 60, and the lower cap 90 may be
temporarily assembled through a fitting structure or an adhesive
tape, and then an insulation foaming agent may be injected and
foamed in the internal space thereof.
[0058] That is, a foaming space 40 in which an insulation material
41 is foamed is formed between the front plate 50 and the rear
plate 70. The insulation material 41 is for insulating the storage
chamber 11, and urethane may be used for the insulation material
41. If the forming process of the insulation foaming agent in the
foaming space 40 is completed, the front plate 50, the rear plate
70, the upper cap 60, and the lower cap 90 may be firmly
coupled.
[0059] Meanwhile, a display unit 100 configured to display
operation information of the refrigerator or receive operation
commands of the refrigerator is provided in the door 22. The
display unit 100 may be provided to be in close contact with the
rear surface of the front plate 50.
[0060] The display unit 100 may be received and supported in the
upper cap 60 coupled to an upper portion of the front plate 50.
That is, the upper cap 60 of the door 22 may serve to support the
display unit 100. However, the display unit 100 may be provided to
be supported by a separate supporting member other than the upper
cap 60.
[0061] The display unit 100 may be fixed so that a display part 111
is located at a position corresponding to the through-holes of the
front plate 50.
[0062] The upper cap 60 includes a body part 63, and a receiving
space 64 configured to be formed in the body part 63 so that a
front surface thereof is opened to receive the display unit 100.
That is, the receiving space 64 has a groove shape formed at the
front side of the body part 63. Further, an insertion groove 62 is
formed in an upper surface 61 of the upper cap 60 to insert the
display unit 100 into the receiving space 64.
[0063] The front surface of the receiving space 64 is opened to
allow light of the display part 111 of the display unit 100 to be
emitted to the through holes 51 of the front plate 50.
[0064] A guide member 65 configured to press the display unit 100
frontward so that the display unit 100 is in close contact with the
front plate 50 may be provided in the receiving space 64. The guide
member 65 may protrude frontward from the body part 63. The guide
member 65 may have an overall gentle curve to guide movement of the
display unit 100 inserted downward from an upper side thereof. The
guide member 65 may be configured as an elastic member having an
elastic force.
[0065] When the insulation foaming agent is injected and foamed in
the foaming space 40, the insulation foaming agent should not
permeate the receiving space 64. To this end, the upper cap 60 is
disposed so that the front surface of the body part 61 is in close
contact with the rear surface of the front plate 50.
[0066] As the body part 61 of the upper cap 60 is in close contact
with the rear surface of the front plate 50, the receiving space 64
defined in the body part 61 may be separately partitioned from the
foaming space 40. That is, the top and bottom and left and right
sides and the rear side of the receiving space 64 may be covered by
the body part 61, and the front side thereof may be covered by the
rear surface of the front plate 50.
[0067] A sealing member 67 may be provided at the front surface of
the body part 61 to hermetically secure of the foaming space 40.
The sealing member 67 may include an elastic material such as
rubber. When the upper cap 60 is coupled to the upper portion of
the front plate 50, the sealing member 67 may be in close contact
with the rear surface of the front plate 50 and thus may
hermetically seal the receiving space 64 as an independent
space.
[0068] The upper cap 60 may further include a cover 68 configured
to seal the insertion groove 62 after the display unit 100 is
inserted into the receiving space 64. The cover 68 may have a
pressing part 69 configured to press the display unit 100 and to
prevent the display unit 100 from moving up and down.
[0069] In the embodiment, the receiving space 64 configured to
receive the display unit 100 and the body part 63 configured to
separately partition the receiving space 64 from the foaming space
40 are integrally formed at the upper cap 60, but the present
disclosure is not limited thereto. The receiving space 64 and the
body part 63 may be separately provided from the upper cap 60 and
then fixedly coupled to the upper cap 60.
[0070] By such structure, the display unit 100 may be installed in
the door 21, and the display unit 100 is prevented from being
exposed to the outside of the door. However, when particular
information is displayed through the display unit 100, the
information may be displayed to the outside through the plurality
of through-holes 51 of the front plate 50.
[0071] FIG. 4 is a view illustrating a state in which the display
unit of the refrigerator of FIG. 1 is disassembled.
[0072] Referring to FIG. 4, the display unit 100 may include a
cover sheet 110, a light source 130 configured to emit light, and a
guide part 120 configured to guide the light emitted from the light
source 130 to the display part 111.
[0073] The cover sheet 110 may include the display part configured
to brighten or darken and thus to display the operation information
of the refrigerator, and a counteraction part 112 configured to be
maintained in a relatively dark state. The display part 111 may be
formed of a transparent material or a fluorescent material, and the
counteraction part 112 may be formed of an opaque material.
[0074] The cover sheet 110 may be separately provided from the
guide part 120 and then adhered to one surface of the guide part
120.
[0075] The display part 111 may be configured with one of a pattern
111a, a character 111b, a numeral and a symbol indicating the
operation information of the refrigerator, and one of segments 111c
partially forming the pattern 111a, the character 111b, the numeral
and the symbol, or the combination thereof. Therefore, when the
light illuminates the cover sheet 110, the pattern 111a, the
character 111b, the numeral, the symbol or the like brightens and
thus the operation information of the refrigerator may be
displayed.
[0076] The light source 130 may include LEDs 131 and a printed
circuit board 132 on which the LEDs 131 are mounted, and a
connector 133 to which a power source is connected. The plurality
of LEDs 131 may be provided to be independently controlled.
[0077] The guide part 120 guides the light emitted from the LEDs
131 to the cover sheet 110. The guide part 120 includes a body part
121 formed of a material reflecting the light, and a guide hole 122
configured to pass through the body part 121. As illustrated in
FIGS. 7 and 8, the guide hole 122 may be formed so that a size
thereof is gradually increased from the LEDs 131 toward the cover
sheet 110.
[0078] Meanwhile, the display unit 100 may further include an input
part configured to receive the operation commands of the
refrigerator. The input part may be configured in a capacitive
touch sensing manner.
[0079] As an example, the input part may include a spring-shaped
touch button 140, and a sensor (not shown) configured to measure a
change in an electric charge according to the user's touch. The
touch button 140 is mounted on the printed circuit board 132 to
pass through a button hole 123 of the guide part 120 and then to be
in contact with the cover sheet 110.
[0080] When a user touches a particular area of the front plate
corresponding to a position of the touch button 140, the sensor may
measure the change in the electric charge flowing through the touch
button 140 and sense whether the user touches. The input part may
employ various methods such as a resistive method, a dome switch
method, and a proximity sensing method, for example.
[0081] Meanwhile, the display part 111 may be integrally formed
with the guide part 120. In this case, the cover sheet may not be
separately provided at the display unit 100.
[0082] FIG. 5 is an enlarged view illustrating the vicinity of
through-holes of the front plate of the refrigerator of FIG. 1.
FIG. 6 is an enlarged view illustrating the vicinity of the
through-holes of the front plate in a state in which the display
unit of the refrigerator of FIG. 1 is turned off. FIG. 7 is a
cross-sectional view taken along a line B-B of FIG. 5. FIG. 8 is a
view illustrating a state in which the through-holes in FIG. 7 are
filled with a filler member.
[0083] Referring to FIGS. 5 to 8, when the particular information
is displayed on the display unit hidden in the door 21, the
information may be displayed through the plurality of through-holes
51 formed in the front plate 50 of the door 21, as illustrated in
FIG. 5.
[0084] Each of the through-holes 51 formed in the front plate 50
may have a diameter of approximately 0.1 mm to approximately 0.5
mm, and a gap between the through-holes 51 may be approximately 0.3
mm to approximately 1.5 mm. The through-holes 51 may be observed by
the user's naked eye. At this time, it is assumed that a thickness
of the front plate 50 is approximately 0.6 mm.
[0085] The through-holes 51 may be formed through an etching
process or a laser drilling process. When the size of the
through-hole 51 is within a range of approximately 0.3 mm to
approximately 0.4 mm, an etching process having high accuracy may
be suitable.
[0086] When the size of the through-hole 51 is approximately 0.2 mm
or less, the laser drilling process may be used, even though slight
thermal deformation or burrs may be generated. Meanwhile, in the
case of a relatively small shape, if the size of the through-hole
51 is great, discrimination thereof is reduced, and thus the
through-hole 51 may have a size of approximately 0.2 mm or
less.
[0087] As an example, in FIG. 3, the size of each through-hole 51c
corresponding to the segments 111c partially forming the numeral
may be within a range of approximately 0.3 mm to approximately 0.4
mm, and the size of each through-hole 51a and 51b corresponding to
the small pattern 111a and the small character 111b may be
approximately 0.2 mm or less. The through-holes 51 are formed in a
predetermined area corresponding to the display part 111 of the
display unit 100.
[0088] That is, the through-holes 51 may be arranged to form shapes
of the segments 51c or the like of the pattern 51a, the character
51b, and the numeral corresponding to the segments 111c or the like
of the pattern 111a, the character 111b, and the numeral of the
display part 111. Therefore, when the LEDs 131 emit light, and the
pattern, the character, the numeral, the symbol, or the like is
displayed on the display unit 100, the particular pattern,
character, numeral, symbol, or the like may be displayed on the
front plate 50 of the door.
[0089] As illustrated in FIG. 7, as a result, the light emitted
from the LEDs 131 of the printed circuit board 132 may pass
sequentially through the guide hole 122 of the guide part 120, the
display part 111 of the cover sheet 110, and the plurality of
through-holes 51 of the front plate 50, and then may be viewed by
the user.
[0090] Meanwhile, as illustrated in FIG. 8, the through-holes 51
may be filled with a filler member 52 to prevent foreign substances
from being inserted into the through-holes 51 and thus to prevent
the through-holes 51 from being clogged.
[0091] The filler member 52 may include the transparent material or
the fluorescent material. The filler member 52 may be a silicone
resin or a UV resin. The filler member 52 may be filled in the
plurality of through-holes 51 through a manner of coating a
silicone or UV paint on the front plate 50.
[0092] FIG. 9 is a view illustrating a state in which an error is
generated while the through-holes are coated with the filler member
in accordance with the embodiment of the present disclosure. FIG.
10 is a view illustrating a state in which air is removed from the
through-holes of FIG. 9 using a vacuum apparatus. FIG. 11 is a flow
chart illustrating an entire process of filling the through-holes
with the filler member in accordance with an embodiment of the
present disclosure.
[0093] Referring to FIGS. 9 to 11, a process of filling the
through-holes with the filler member in accordance with the
embodiment of the present disclosure will be described. Here, as an
example, the UV paint is used for the filler member. Hereinafter,
the filler member, the UV paint, and the paint all refer to the
same thing.
[0094] As illustrated in FIG. 11, the process of filling the
through-holes with the filler member in accordance with the
embodiment of the present disclosure includes operation 310 of
coating with a protection vinyl, operation 320 of coating with a
paint, operation 330 of removing air, squeegee operation 340 of
squeezing overflowed filler member, operation 350 of curing the UV
paint, and inspection operation 360.
[0095] In operation 310 of coating with the protection vinyl, the
protection vinyl 200 is coated to block one or both side openings
of the through-holes 51. In the embodiment, the protection vinyl
200 is coated on the front surface 50a of the front plate 50.
However, the present disclosure is not limited thereto, and the
protection vinyl 200 may be coated on the rear surface 50b of the
front plate 50.
[0096] The protection vinyl 200 should be coated to be in close
contact with the front surface 50a of the front plate 50 and thus
to prevent the paint 52 from leaking. When the process of filling
the through-holes 51 with the paint 52 is completed, the protection
vinyl 200 may be stripped away.
[0097] Polyethylene (PE), polyethylene terephthalate (PET), and
oriented polypropylene (OPP) materials may be used for the
protection vinyl 200.
[0098] However, compared to the other materials, air generation in
the through-holes 51 may be further reduced when the polyethylene
material is used.
[0099] In operation 320 of coating with the paint, the UV paint is
substantially coated in the through-holes 51. Because the
protection vinyl 200 is coated on the front surface 50a of the
front plate 50, the paint is coated in the through-holes 51 through
an entrance of each through-hole 51 which is formed at the rear
surface 50b of the front plate 50.
[0100] The coating of the paint may be performed by immersing the
front plate 50 in a container filled with the paint.
[0101] If possible, the paint may have a high viscosity. If the
paint has a high viscosity, the through-holes 51 may be completely
filled without any unfilled area. The paint may have a viscosity of
approximately 2000 centipoise (cP) or more.
[0102] As illustrated in FIG. 9, when the paint 52 is coated,
during the process of coating all of the through-holes 51 with the
paint, coating the paint 52 to the extent that it overflows from
inner sides of the through-holes 51 may be unavoidable. That is,
the paint may be slightly disposed on the rear surface 50b of the
front plate 50 during coating.
[0103] For convenience of explanation, a part of the paint 52
disposed on the rear surface 50b of the front plate 50 but not in
the through-holes 51 is referred to as an overflowed portion 52a.
As described later, the overflowed portion 52a is removed in the
squeegee operation.
[0104] Meanwhile, as illustrated in FIG. 9, air 210 may be
generated in the through-holes 51 while the paint 52 is coated. The
air 210 prevents parts of the inner sides of the through-holes 51
from being coated with the paint. Further, the air 210 may push the
paint to the protection vinyl 200. Therefore, a state in which the
through-holes are filled with the paint 52 may be poor, and may
affect an appearance of the display.
[0105] In order to prevent such a phenomenon, when the coating of
the paint is completed, the process of removing the air 210
generated in the through-holes 51 is performed. The removing of the
air may be achieved by removing the air 210 using a vacuum
apparatus. A state in which the air 210 is removed is illustrated
in FIG. 10.
[0106] Squeegee operation 340 is a leveling process in which the
above-mentioned overflowed portion 52a of the paint 52 is removed.
Squeegee operation 340 may be performed by squeezing the rear
surface 50b of the front plate 50 using a rolling pin. As described
later, the squeegee operation may not be needed according to the
shapes of the through-holes.
[0107] In operation 350 of curing the UV paint, ultraviolet light
is radiated to the completely coated UV paint to cure the UV
paint.
[0108] In inspection operation 360, a state in which the UV paint
is filled is finally inspected.
[0109] FIG. 12 is a view illustrating a state in which the
through-holes are coated with the filler member in accordance with
the embodiment of the present disclosure. FIG. 13 is a flow chart
illustrating a process of filling the through-holes with the filler
member in accordance with an embodiment of the present
disclosure.
[0110] As described above, the squeegee operation may not be needed
according to the shapes of the through-holes. As an example, as
illustrated in FIG. 12, when the front plate 50 is half-etched and
includes a half-cut portion 410 and a through-hole portion 420, the
squeegee operation is not needed.
[0111] The coating of the paint 52 is performed to coat all of the
through-hole portions 420 with the paint 52, but in the half-cut
portion 410, a part is not coated with the paint 52. That is, when
the front plate 50 is half-cut, the overflow of the paint 52 may
not occur.
[0112] The filling of the paint may be performed through the same
process as previously described except for the squeegee operation.
That is, the operation of filling the through-holes with the filler
member in accordance with an embodiment of the present disclosure
may include operation 510 of coating with a protection vinyl,
operation 520 of coating with paint, operation 530 of removing air,
operation 540 of curing the UV paint, and inspection operation 550.
Because these operations are the same as those in the previous
embodiment, the description thereof will be omitted.
[0113] Through this filling method, the air in the through-holes is
removed, and a sealing member may be filled in the through-holes
without the overflow of the sealing member, and thus an appearance
of the door may be enhanced.
[0114] The above-mentioned method of filling the sealing member 67
in the through-holes 51 is not applied only to the front plate 50
of the door of the refrigerator. This method may also be applied
when the sealing member is filled in the through-holes formed in
general steel plates other than the door of the refrigerator.
[0115] FIG. 14 is a view illustrating a relationship between a
thickness of the front plate of the refrigerator and a size of each
of the through-holes in accordance with an embodiment of the
present disclosure. FIG. 15 is a view illustrating the relationship
between the thickness of the front plate of the refrigerator and
the size of each of the through-holes when the front plate of the
refrigerator is half-cut in accordance with an embodiment of the
present disclosure.
[0116] With reference to FIGS. 14 and 15, a viewing angle of the
display unit will be described. Because the display unit 100 of the
refrigerator according to the embodiment of the present disclosure
is provided to be hidden in the front plate 50, and exposed to the
user through the through-holes 51 of the front plate 50, it is
necessary to secure a sufficient viewing angle at which the user
may read the information displayed on the display unit 100 easily
even when viewing the refrigerator obliquely.
[0117] As illustrated in FIG. 14, the viewing angle .theta.1 is
defined as an angle which is formed by straight lines connecting
both ends of the diameter of the through hole 51 in the front
surface 50a of the front plate 50 and both ends of the diameter of
the through hole 51 in the rear surface 50b of the front plate
50.
[0118] The viewing angle .theta.1 may be minutely changed according
to the materials of the front plate 50 and the filler member 52,
and the machined state of the through-holes 51, i.e., the
squareness of the front, or whether there are foreign substances
after the machining process.
[0119] However, it is assumed that the viewing angle .theta.1 is
determined by a thickness T1 of the front plate 50 and a size R1 of
the through hole 51.
[0120] The viewing angle .theta.1 may be in inverse proportion to
the thickness T1 of the front plate 50, and in proportion to the
size R1 of the through hole 51.
[0121] If the thickness T1 of the front plate 50 and the size R1 of
the through hole 51 are equal, the viewing angle .theta.1 may be
90.degree., if the size R1 of the through hole 51 is smaller than
the thickness T1 of the front plate 50, the viewing angle .theta.1
may be an acute angle, and if the size R1 of the through hole 51 is
larger than the thickness T1 of the front plate 50, the viewing
angle .theta.1 may be an obtuse angle.
[0122] In a service environment in which the user uses the
refrigerator in the kitchen or the like, the suitability of the
view angle according to the thickness of the front plate 50 of the
door of the refrigerator and the size of the through-hole 51
thereof may be determined as shown in the following Table 1.
TABLE-US-00001 TABLE 1 When the front plate is not half-cut
Thickness 0.6 0.3 0.2 of front plate (T1, mm) Diameter 0.1 0.3 0.4
0.5 0.3 0.2 of through- hole (R1, mm) Suitability unsuitable
unsuitable suitable suitable suitable suitable of viewing angle
(.theta.1)
[0123] As shown in Table 1, it may be understood that, when the
thickness T1 of the front plate is 0.6 mm, the diameter R1 of the
through-hole should be more than 0.3 mm to have the suitable
viewing angle .theta.1. It may also be understood that, when the
thickness T1 of the front plate is 0.3 mm and 0.2 mm, the diameter
R1 of the through-hole should be 0.3 mm and 0.2 mm to have the
suitable viewing angle .theta.1.
[0124] According to the above-mentioned results, the relationship
between the diameter R1 of the through-hole and the thickness T1 of
the front plate for securing the sufficient viewing angle .theta.1
will be defined as the following equation.
R1>T1/2 (Equation 1)
[0125] However, when the front plate 50 is half-cut, the
relationships among the viewing angle, the diameter of the
through-hole and the thickness of the front plate may be
changed.
[0126] As illustrated in FIG. 15 and Table 2 below, in the case in
which the front plate 50 is half-cut and includes a half-cut
portion 410 and a through-hole portion 420, when a thickness T2 of
the front plate is 0.6 mm and a diameter R2 of the through-hole is
0.3 mm, a suitable viewing angle .theta.2 is provided. Here, the
half-cutting means that a half of the thickness T2 of the front
plate 50 is cut.
[0127] That is, when the front plate 50 is not half-cut, if the
thickness T1 of the front plate is 0.6 mm and the diameter R1 of
the through-hole is 0.3 mm, the viewing angle .theta.1 is not
sufficient. However, when the front plate 50 is half-cut, if the
thickness T2 of the front plate is 0.6 mm and the diameter R2 of
the through-hole is 0.3 mm, the viewing angle .theta.2 is
sufficient.
[0128] In the following Table 2, because it is difficult to perform
the half-cutting when the thickness T2 of the front plate is 0.1
mm, the suitability of the viewing angle may not be determined. In
other cases, because the sufficient viewing angle may be secured
without performing the half-cutting as shown in Table 1, and thus
the half-cutting is not needed, it should be noted that the
suitability of the viewing angle is not determined.
TABLE-US-00002 TABLE 2 When the front plate is half-cut Thickness
0.6 0.3 0.2 of front plate (T2, mm) Diameter of 0.1 0.3 0.4 0.5 0.3
0.2 through- hole (R2, mm) Suitability of -- Suitable -- -- -- --
viewing angle (.theta.2)
[0129] According to the above-mentioned results, when the front
plate is half-cut, the relationship between the diameter R2 of the
through-hole and the thickness T2 of the front plate for securing
the sufficient viewing angle .theta.2 will be defined as the
following equation.
R2.gtoreq.T2/2 (Equation 2)
[0130] That is, in the case in which the front plate is half-cut,
when the diameter R2 of the through-hole is greater than or equal
to half the thickness of the front plate, a sufficient viewing
angle may be secured.
[0131] According to embodiments of the present disclosure, the
front plate of the refrigerator is formed of the steel plate, the
display unit is hidden in the door, and information displayed on
the display unit may be seen through the through-holes formed in
the front plate. Therefore, an appearance of an exterior of the
refrigerator may be improved.
[0132] Also, it is possible to minimize the diameters of the
through-holes and to secure a sufficient viewing angle at which the
information displayed on the display unit in the door may be read
easily through through-holes even if the display of the
refrigerator is viewed obliquely.
[0133] Further, it is possible to prevent the generation of
unfilled portions and bubbles when filling the through-holes with
the filler member, and thereby to improve reliability.
[0134] Although a few embodiments of the present disclosure have
been shown and described, it would be appreciated by those skilled
in the art that changes may be made in these embodiments without
departing from the principles and spirit of the disclosure, the
scope of which is defined in the claims and their equivalents.
* * * * *