Cooktop Frame Segmentation to Reduce Mold Cost and Material Waste
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Solution Overview
Problem
Conventional cooktop frame manufacturing requires expensive materials with high elongation and large-sized molds, increasing production costs and material waste due to the need for a drawing process.
Innovation Solution
The cooktop frame is manufactured using miniaturized molds and stainless steel sheets with lower elongation, processed into two separate frames without the drawing process, reducing material waste and mold costs.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Shape
If a drawing process is used to form the frame, then the frame shape can be formed, but expensive materials with high elongation are required and large-sized molds are needed, increasing manufacturing cost
Solution Approach 1:
The frame is divided into multiple separate components (side frames and top frame) that are manufactured independently using pressing processes with miniaturized molds, then assembled together. This segmentation eliminates the need for a single large mold and complex drawing process, reducing both mold costs and material requirements while maintaining the overall frame shape.
2Shape
If a drawing process is used to form the frame, then the frame can be formed, but material waste increases due to the requirements of the process
Solution Approach 1:
The frame components are pre-formed using pressing processes with miniaturized molds that closely match the final component shapes, minimizing material waste from the outset. The notching and piercing operations are performed on smaller, more efficiently shaped materials rather than requiring excessive material for a large drawing mold.
3Ease of manufacture
If miniaturized molds are used, then manufacturing cost decreases, but the frame structure must be redesigned
Solution Approach 1:
The frame is segmented into multiple components (side frames and top frame) that can each be manufactured using miniaturized molds. This segmentation, while requiring assembly, enables the use of smaller, more cost-effective molds and materials, with the overall structural integrity maintained through proper connection design.
Data Source
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AI summary
Provided is a cooker which has a frame forming a side plate, which can be easily manufactured and can reduce manufacturing cost. The cooker includes a cooktop assembly for cooking and directly heating a container in which food is accommodated. The cooktop assembly includes a side plate having at least two frames coupled to each other, and a top plate located at an upper portion of the side plate.