Corner Member Panel Assembly to Eliminate Welding and Grinding Defects
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Solution Overview
Problem
Conventional frame panel manufacturing for electronic appliances like dishwashers results in sharp edges and rough surfaces due to welding, which affects aesthetics and safety, and involves additional processes like grinding that can strip coatings and alter the metal's color.
Innovation Solution
A panel assembly featuring a corner member made of synthetic resin, integrated with a metal frame panel to form a seamless, curved edge without the need for separate welding or grinding, using exposed and buried portions that are molded to fit seamlessly with the frame panel, preventing coating peeling and color changes.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If welding is used to join joints of the frame panel, then the structural strength is improved, but the surface becomes rough and the coating peels off
Solution Approach 1:
The patent extracts the welding process from the frame panel manufacturing by using a corner member that mechanically joins the metal plate surfaces without welding. The corner member is inserted into a groove formed at the joint of the metal plate, eliminating the need for welding and thus preventing surface roughness and coating peeling while maintaining structural strength.
Solution Approach 2:
The corner member acts as an intermediary component between the metal plate surfaces. Instead of directly welding the metal plate joints, the corner member mediates the connection by fitting into the groove and providing structural support, thereby avoiding direct thermal contact that causes surface degradation.
2Shape
If grinding is used to create curved edges, then the aesthetics are improved, but the coating peels off and the metal color changes
Solution Approach 1:
The corner member is pre-formed with a curved shape that provides the desired aesthetic appearance. By inserting this pre-shaped corner member into the groove, the curved edge effect is achieved without performing grinding operations on the metal plate, thus preserving the coating and original metal color.
Solution Approach 2:
The corner member serves as a copy or replica of the desired curved edge shape. Instead of directly shaping the metal plate through grinding, the design copies the aesthetic effect by attaching a separately formed corner member with the appropriate curvature, avoiding damage to the original metal plate surface.
3Stability of the object's composition
If separate welding process is added to join frame panel surfaces, then the structural integrity is improved, but the manufacturing complexity increases
Solution Approach 1:
The patent merges the corner member insertion process with the frame panel assembly process. The groove is formed during the metal plate bending process, and the corner member is inserted in the same assembly sequence, eliminating the need for a separate welding process and reducing manufacturing complexity while maintaining structural integrity.
Data Source
AI summary
A panel assembly including a corner member is provided. The panel assembly according to an exemplary embodiment of the present disclosure includes: a frame panel consisting of one sheet of metal plate and having a front surface, an upper surface bent from the front surface, and a side surface bent from the front surface; and a corner member coupled with a gap formed between the upper surface of the frame panel and the side surface of the frame panel, in which the corner member includes an exposed portion exposed to the outside and a buried portion covered with the upper surface or the side surface of the frame panel.