Cooker Inner Box Calked Flange Structure for Warp-Free Shielding
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Conventional inner box for a cooker experiences warping and radio wave leakage due to the play between fold-to-bend portions during the calking process, requiring large equipment and high pressure, and insulating surface treatments hinder electrical conductivity.
Innovation Solution
The inner box design incorporates a first fold-to-bend portion and a second fold-to-bend portion with a predetermined clearance, along with a flange portion that is inserted into this clearance to ensure precise bonding without large equipment, and includes locking holes and projections for secure alignment, allowing for conductive paths even with insulating surface treatments.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If four sheets of face plates are simultaneously calked to bond to the front plate, then bonding efficiency is improved, but considerable pressure is applied to the calking jig and equipment becomes large-sized
Solution Approach 1:
The bonding process is segmented into two stages: first bonding two face plates simultaneously, then bonding the remaining two face plates. This segmentation reduces the pressure required at each stage compared to bonding all four plates simultaneously, while still maintaining higher productivity than sequential bonding of individual plates.
2Stress or pressure
If face plates are successively bonded sheet by sheet, then calking pressure is reduced, but slide amount between fold-to-bend portions increases causing warping
Solution Approach 1:
The fold-to-bend portions are pre-formed with specific geometries (inclined surfaces and positioning protrusions) before the calking process. This preliminary action ensures that during calking, the fold-to-bend portions align precisely with minimal slide amount, preventing warping even when bonding plates successively with reduced pressure.
3Shape
If insulating surface treatment is applied to face plates, then appearance quality is improved, but electrical conductivity is lost causing radio wave leakage
Solution Approach 1:
The fold-to-bend portions are designed with localized conductive features (positioning protrusions and corresponding recesses) that maintain electrical conductivity only at the bonding interfaces, while the rest of the face plates retain insulating surface treatments for appearance quality. This local quality approach ensures radio wave shielding at critical points without sacrificing overall aesthetic appearance.
Data Source
AI summary
An inner box for a cooker is provided including a front plate having an opening portion and an inner box main body bonded to a peripheral edge of the opening portion comprising a first fold-to-bend portion constituted by folding to bend an end portion thereof to invert to be brought into close contact therewith and a second fold-to-bend portion constituted by inverting a portion on a side of the end portion of the first fold-to-bend portion with a predetermined clearance therebetween and a flange portion inserted into the clearance between the first fold-to-bend portion and the second fold-to-bend portion, and wherein the bonding portions of the front plate and the inner box main body are constituted by a structure of inserting the flange portion into the clearance to be calked to bond therewith.