Bent Wire Refrigerator Shelf Support Without Welding

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Solution Overview

Problem

Existing refrigerator shelves with wire support rods require welding, increasing labor and inventory costs, and using more material than necessary, while still needing to meet industry standards for deflection, strength, and retention.

Innovation Solution

A single piece of bent wire support rod is used under only a portion of the shelf perimeter, eliminating the need for welding and reducing material usage, with specific bends providing support and engagement with retention elements to meet industry requirements.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Strength

If wire support rods are used to meet industry standards for shelf strength and deflection, then structural integrity is improved, but manufacturing complexity and labor costs increase due to welding requirements

Engineering Contradiction:
Improveshelf strengthVSAvoidmanufacturing complexity
Core Design Contradiction:
StrengthVSDevice complexity

Solution Approach 1:

The wire support structure is segmented into discrete bent wire support rods positioned at specific locations beneath the shelf perimeter rather than forming continuous welded structures. Each rod is independently formed and positioned, eliminating welding operations while maintaining structural integrity through strategic placement and geometric configuration.

Inventive Principle:
Principle #1Segmentation

Solution Approach 2:

The welding operation is extracted and eliminated from the manufacturing process. Instead of joining multiple wire segments through welding, the design uses pre-formed bent wire rods that are independently installed, removing the complex welding step while still achieving the required structural strength through optimized rod configuration.

Inventive Principle:
Principle #2Taking out (Extraction)

2Reliability

If wire support rods are used to meet industry standards for shelf retention, then reliability is improved, but material usage increases

Engineering Contradiction:
Improveshelf retentionVSAvoidmaterial usage
Core Design Contradiction:
ReliabilityVSLoss of substance

Solution Approach 1:

The wire support rods are configured with specific local geometric qualities including bends and contours that engage with retention elements at critical locations. This localized optimization allows the wire material to be concentrated where it provides maximum retention value, reducing overall material usage while maintaining or improving shelf retention performance.

Inventive Principle:
Principle #3Local quality

Solution Approach 2:

The bent wire support rods extend only partially along the shelf perimeter rather than forming complete continuous loops, providing sufficient retention support through strategic partial coverage. This partial action approach reduces material consumption while achieving the necessary retention reliability through optimized positioning and engagement geometry.

Inventive Principle:
Principle #16Partial or excessive action

Data Source

PatentUS9345326B2Refrigerator shelves
Publication Date: 2016.05.24 WHIRLPOOL CORP
  • US9345326B2 patent drawing
  • US9345326B2 patent drawing
  • US9345326B2 patent drawing

AI summary

Refrigerator shelves are disclosed. An example refrigerator shelf includes a substantially planar member, trim along a first edge of the planar member, and a bent continuous wire support rod. The bent rod having a first portion extending along and beneath the trim, a second portion perpendicular to the first portion and extending from the first edge to a point between the first edge and a second edge opposite the first edge, and a third portion extending from the point and extending substantially perpendicularly from a plane defined by the first and second portions.