Appliance Cabinet Bracket Joining Using High-Velocity Metal Forming

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Solution Overview

Problem

Conventional methods for attaching components to appliance cabinets, such as welding or using fasteners, are costly and labor-intensive, involving additional fabrication steps and potential disruptions to hermetic seals.

Innovation Solution

High-velocity metal forming (HVMF) techniques are used to induce plastic flow in metallic cabinet components, allowing for the direct attachment of brackets and hinges without fasteners by moving parts at speeds greater than 100 meters per second, utilizing electromagnetic forces or pulse waves to create a strong, hermetic bond.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Strength

If welding or fasteners are used to attach components to the appliance cabinet, then the attachment strength is improved, but the manufacturing cost and labor intensity increase

Engineering Contradiction:

Improveattachment strengthVSAvoidmanufacturing cost and labor intensity

Core Design Contradiction:

StrengthVSEase of manufacture

Solution Approach 1:

The patent replaces traditional mechanical attachment systems (welding equipment, fastener installation tools) with a high-velocity impact system that uses kinetic energy to plastic deform the wrapper material and form interlocking features. This substitution eliminates the need for separate fastening equipment and reduces labor requirements while maintaining attachment strength.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Solution Approach 2:

The patent combines the attachment process with the existing cabinet fabrication process by integrating the high-velocity impact attachment into the wrapper forming operation. The wrapper is formed and components are attached in a unified manufacturing sequence, eliminating separate fabrication steps for hole formation, fastener installation, or welding operations.

Inventive Principle:

Principle #5Merging (Combining)

2Strength

If welding or fasteners are used to attach components to the appliance cabinet, then the attachment strength is improved, but the manufacturing time increases

Engineering Contradiction:

Improveattachment strengthVSAvoidmanufacturing time

Core Design Contradiction:

StrengthVSProductivity

Solution Approach 1:

The patent enables continuous manufacturing by maintaining the high-velocity impact attachment process as a continuous operation rather than a series of discrete steps. The wrapper material flows continuously through the forming and attachment zones, with components being attached in-line without interruption, thereby reducing total manufacturing time while ensuring strong attachments.

Inventive Principle:

Principle #20Continuity of useful action

Solution Approach 2:

The patent performs preliminary positioning and alignment of components during the wrapper forming process itself, before the high-velocity impact attachment occurs. This preliminary action eliminates the need for separate positioning and alignment steps that would otherwise be required before welding or fastener installation, thereby reducing overall manufacturing time.

Inventive Principle:

Principle #10Preliminary action

3Device complexity

If high-velocity metal forming is used to attach brackets to the cabinet, then the manufacturing complexity is reduced, but the speed requirement increases

Engineering Contradiction:

Improvemanufacturing process complexityVSAvoidimpact speed

Core Design Contradiction:

Device complexityVSSpeed

Solution Approach 1:

The patent changes the velocity parameter of the wrapper material from typical forming speeds to high-velocity impact speeds (greater than 100 feet per second). This parameter change enables the material to plastic deform and form interlocking features with components during the forming process itself, simplifying the overall manufacturing process by eliminating separate attachment operations despite the increased speed requirement.

Inventive Principle:

Principle #35Parameter changes

Applied Scientific Principles

This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.

Function Achieved in This Case

This method eliminates the need for separate manufacturing steps like drilling and welding, reduces manufacturing time and costs, and maintains the hermetic integrity of appliance seals, enabling efficient and cost-effective attachment of components to appliance cabinets.

Implementation Method 1

moving one of a portion of the first metallic tub or the bracket at a speed great enough to induce plastic flow of the portion of the first metallic tub about a portion of the bracket

Methodology Applied

Scientific EffectPlastic flow: Plasticity

Implementation Method 2

utilizing electromagnetic forces or pulse waves to create a strong, hermetic bond

Methodology Applied

Scientific EffectElectromagnetic forces: Lorentz Force

Implementation Method 3

utilizing electromagnetic forces or pulse waves to create a strong, hermetic bond

Methodology Applied

Scientific EffectPulse waves: Shock Wave

Data Source

PatentUS10017971B2Method of making an appliance cabinet

Publication Date: 2018.07.10 WHIRLPOOL CORP

AI summary

An appliance cabinet may be made having at least a first metallic tub, and a mounting bracket by which a component of the appliance may be mounted to the cabinet. The bracket and the first metallic tub may be juxtaposed. The bracket may be attached to the first metallic tub by moving one of a portion of the first metallic tub or the bracket at a speed great enough to induce plastic flow of the portion of the first metallic tub about a portion of the bracket.