Corner Member Panel Assembly to Eliminate Sharp Welded Edges
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Solution Overview
Problem
Metal frame panels in home appliances often have sharp corners formed during the welding process, which degrade the aesthetic appeal and can be hazardous to users, while existing manufacturing methods are complex and costly.
Innovation Solution
A panel assembly featuring a frame panel with a corner member made of synthetic resin, which fills the gaps between the metal frame's surfaces, eliminating sharp edges and simplifying the manufacturing process by avoiding welding, with the corner member being integrally formed with a fixing member to secure it to the frame panel.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If welding is used to join frame panel surfaces, then structural strength is improved, but sharp corners are formed degrading aesthetic impression and causing safety hazards
Solution Approach 1:
A corner member made of soft material (e.g., rubber, foam, or plastic) is introduced as an intermediary element between the metal frame panel surfaces. This corner member fills the gap at the corner region, covering the sharp corner formed by welding while maintaining the structural integrity of the frame panel. The corner member can be attached via adhesive, mechanical fasteners, or snap-fit mechanisms.
Solution Approach 2:
The frame panel is divided into separate surfaces that are joined through welding, with the corner region treated as a distinct segment. The corner member is applied specifically to this segmented corner region, allowing the main structural joints to be welded for strength while the corner segment is treated separately to eliminate sharp edges.
2Stability of the object's composition
If traditional frame panel manufacturing with welding is used, then structural integrity is improved, but manufacturing complexity and cost increase
Solution Approach 1:
The corner members are pre-manufactured separately from the frame panel, allowing the main frame panel to be produced through simpler welding processes. The corner members are then attached in a subsequent assembly step, separating the complex corner treatment from the main manufacturing process and enabling parallel production of components.
Solution Approach 2:
The corner member serves as a mediator that simplifies the overall manufacturing process by replacing complex corner welding and finishing operations with a standardized pre-manufactured component that can be easily attached to the frame panel.
3Shape
If corner members are added to fill gaps between surfaces, then aesthetic impression is improved, but device complexity increases
Solution Approach 1:
The corner member combines multiple functions into a single component: it fills the gap between frame panel surfaces, covers sharp corners, provides aesthetic finishing, and can also serve as a mounting surface for other components. This merging of functions reduces the need for separate elements and simplifies the overall device structure.
Solution Approach 2:
The corner member is designed as a universal component that can be applied to various corner configurations and can serve multiple purposes including aesthetic covering, safety protection, and potential mounting functions, thereby justifying the added element through its multi-functionality.
Data Source
AI summary
A panel assembly includes a frame panel including a front surface, an upper surface, a side surface, and a rear surface and is formed as a single sheet of a metal plate, and a corner member disposed in a gap formed between the upper surface of the frame panel and the side surface of the frame panel, wherein the corner member includes: an insertion member inserted into the gap to fill the gap, and a fixing member integrally formed with the insertion member and coupled to the rear surface of the frame panel to fix the corner member to the frame panel.