Dishwasher Door Hood Corner Joint Without Welded Seams
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Solution Overview
Problem
The production of the hood-shaped sheet metal part in dishwashers is complex due to the need for a welded connection between the roof and side walls, which can damage the surface structure and is technically challenging, especially when the sheet metal is not weldable or coated.
Innovation Solution
A free corner cutout is created at the corner area between the roof and side walls of the hood-shaped sheet metal part, allowing a shaped corner of the inner component carrier to serve as a connecting surface, eliminating the need for a welded connection and enabling a simpler production process, even when the sheet metal surface is coated.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If a welded connection is used to connect the roof and side walls of the hood-shaped sheet metal part, then a stable corner connection is achieved, but the production process becomes complex and the surface structure can be damaged
Solution Approach 1:
A plastic corner piece serves as an intermediary component between the roof and side walls of the sheet metal part. This corner piece is inserted into a corner cutout and provides a connecting surface that joins the roof and side walls without requiring welding. The intermediary component resolves the contradiction by achieving stable connection while avoiding the complexity and surface damage associated with welded connections.
2Strength
If a welded connection is used to connect the roof and side walls, then structural stability is improved, but the sheet metal surface can be damaged and welding may not be possible with coated materials
Solution Approach 1:
The plastic corner piece acts as a mediator that connects the roof and side walls without direct metal-to-metal welding. By introducing this intermediary component, the connection is achieved through mechanical insertion and forming, which preserves the coated sheet metal surface and eliminates the harmful effects of welding on surface integrity.
3Reliability
If welding is used for corner connection, then a reliable joint is achieved, but the production time increases due to additional work steps
Solution Approach 1:
The plastic corner piece enables a simplified production process where the corner connection is achieved through insertion and forming operations rather than welding. This intermediary component allows for faster production while maintaining reliable joints, as the corner piece can be pre-formed and simply inserted into the corner cutout, eliminating the time-consuming welding process.
Data Source
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AI summary
The dishwasher comprises an appliance door, which has an operating unit with an inner component support (19). An electronic component (21) and operating and display elements are enclosed by a dome-shaped sheet metal portion (23). A corner section (35) is provided at a corner area (33) between a top wall (25) and one of the side walls.