Cooking appliance having a component formed from a thin rigid sheet material

The invention transitions from a single-layer sheet material to a multi-layer sheet material structure. By stacking multiple thin layers and forming collars around through-holes that interengage between layers, the solution effectively increases the functional thickness at the connection point without increasing the overall component thickness, enabling reliable screw connections while maintaining the lightweight advantage of thin sheet materials.

The collars of adjacent layers are nested around the same through-hole in a concentric arrangement. The collar of one layer fits within or alongside the collar of another layer, creating a nested structure that distributes the mechanical load across multiple layers and provides sufficient material thickness for secure screw engagement while maintaining a compact overall structure.

By stacking multiple thin layers to create a multi-layer structure with collars, the invention effectively increases the material thickness at the through-hole region. This enhanced thickness provides sufficient barrier properties to maintain microwave tightness while preserving the overall lightweight and cost-effective advantage of using thin sheet materials throughout the component.

The nested arrangement of collars from multiple layers around the through-hole creates a concentric barrier structure that effectively seals the opening. This nested collar configuration provides enhanced microwave tightness by creating multiple overlapping barriers, preventing microwave leakage while maintaining the component's overall thin profile and lightweight characteristics.

The invention maintains cost-effectiveness by continuing to use thin sheet materials but arranges multiple layers in a stacked configuration. This multi-layer approach provides sufficient material thickness for reliable screw connections without requiring expensive thick materials or complex manufacturing processes, achieving a balance between cost-effectiveness and connection reliability.

The nested collar structure distributes mechanical stresses across multiple layers, preventing stress concentration that would lead to failure. This configuration enhances the reliability of screw connections in thin sheet materials while maintaining the simplicity and cost-effectiveness of the manufacturing process, as the nested structure can be formed using standard forming techniques.