Console Shell with Integral Shoulders for Edge-to-Edge Lid Attachment

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Solution Overview

Problem

Conventional laundry appliances with edge-to-edge doors require costly and complex attachment members to couple the door to the console, increasing manufacturing and production costs.

Innovation Solution

A console shell with integrally formed left and right shoulders extending from the console shell towards the front of the cabinet, where the edge-to-edge lid is coupled via wire hinges or rotary dampers, reducing the need for additional attachment components and simplifying the manufacturing process.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If conventional attachment members are used to couple the door to the console, then the door can be securely attached, but the manufacturing and production costs increase

Engineering Contradiction:

Improvedoor attachment securityVSAvoidmanufacturing cost

Core Design Contradiction:

ReliabilityVSEase of manufacture

Solution Approach 1:

The console shell is designed with integrally formed shoulders that are molded as a single piece with the main console body. This eliminates the need for separate attachment members and reduces assembly steps, thereby lowering manufacturing costs while maintaining secure door attachment through the integrated shoulder structures

Inventive Principle:

Principle #5Merging (Combining)

2Reliability

If conventional attachment members are used to couple the door to the console, then the door can be securely attached, but the device complexity increases

Engineering Contradiction:

Improvedoor attachment securityVSAvoidattachment component complexity

Core Design Contradiction:

ReliabilityVSDevice complexity

Solution Approach 1:

The console shell integrates the attachment functionality directly into the shell structure through molded-in shoulders. This consolidation reduces the number of discrete components from multiple separate attachment members to a single integrated console shell assembly, simplifying the overall device structure while maintaining secure door coupling

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The console shell serves multiple functions: it provides the structural housing for the console, contains the integrated shoulder attachment structures, and directly couples the door without requiring separate attachment members. This multi-functionality reduces component complexity while maintaining attachment reliability

Inventive Principle:

Principle #6Universality (Multi-functionality)

Data Source

PatentUS10604881B1Console shell for a laundry appliance

Publication Date: 2020.03.31 WHIRLPOOL CORP

AI summary

A laundry appliance includes a cabinet and a top panel coupled to a top edge of the cabinet. A console shell is coupled to the top panel. The console shell defined left and right shoulders extending from the console shell towards a front of the cabinet. An edge-to-edge lid is coupled to the left and right shoulders via left and right wire hinges, respectively.