Dishwasher Spray Arm Joining Seam for Fluid-Tight Plastic Assembly
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Solution Overview
Problem
The production of spray apparatuses for dishwashers is time-consuming and cost-intensive due to the requirement of metal materials and complex manufacturing processes, such as edge-forming and butt welding, which can lead to material tension and twisting issues.
Innovation Solution
A spray apparatus with a joining seam made from an additional material, applied using an injection process, which forms interfaces between the seam and the shaped components, allowing for a cost-effective and fluid-tight hollow space without the need for additional process steps like butt welding, enabling fully automatic production from plastic components.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If edge-forming and butt welding are used to join shaped components, then a fluid-tight hollow space is formed, but the production becomes time-consuming and cost-intensive
Solution Approach 1:
The patent combines the joining function and sealing function into a single injection-molded joining seam made from additional material. This eliminates the need for separate edge-forming and welding operations, as the joining seam simultaneously bonds the shaped components together and creates the fluid-tight seal, thereby reducing production steps and improving efficiency while maintaining reliability
Solution Approach 2:
The joining seam made from additional material acts as an intermediary substance that facilitates the connection between shaped components. This mediator material is injected into the joint region to form a bonding seam that both joins the components and seals the hollow space, replacing complex mechanical joining processes with a simpler injection molding process
2Reliability
If butt welding with heat reflectors is used to join thermoplastic components, then a fluid-tight hollow space is formed, but material tension builds up leading to twisting of the spray arm
Solution Approach 1:
The joining seam made from additional material serves as a stress-absorbing intermediary that distributes thermal and mechanical stresses uniformly across the joint region. This mediator layer prevents concentration of material tension that would otherwise cause twisting, while still achieving reliable bonding and fluid-tight sealing between the shaped components
Solution Approach 2:
The patent changes the material parameters by introducing a joining seam made from additional material with different thermal and mechanical properties. This additional material layer modifies the stress distribution characteristics during cooling and solidification, preventing the buildup of internal tensions that lead to structural distortion and twisting
3Reliability
If multiple production steps and differently constructed production machines are used for edge-forming and welding, then a spray apparatus is manufactured, but the manufacturing process becomes complex and costly
Solution Approach 1:
The patent merges multiple manufacturing functions (joining and sealing) into a single injection molding process. The injection molding machine introduces additional material that simultaneously performs both the joining and sealing functions, eliminating the need for separate edge-forming equipment and welding machinery, thereby simplifying the manufacturing process and reducing costs while maintaining joint strength
Solution Approach 2:
The joining seam made from additional material performs multiple functions simultaneously: it bonds the shaped components together, seals the hollow space to ensure fluid-tightness, and distributes thermal stresses during cooling. This multi-functional element replaces multiple specialized process steps, reducing manufacturing complexity while achieving reliable results
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
This method reduces manufacturing costs and eliminates material tension, allowing for a cost-effective, fluid-tight, and automatically producible spray apparatus with improved hydraulic design and integration of components like venturi pipes, ensuring efficient and reliable operation.
Implementation Method 1
A spray apparatus with a joining seam made from an additional material, applied using an injection process
Data Source
AI summary
A dishwasher having a crockery basket for holding items to be washed and a spray apparatus including a first contoured body portion having a first edge, a second contoured body portion having a second edge which corresponds to the first edge wherein the first contoured body portion is joined to the second contoured body portion to form a fluid-tight hollow space therebetween and a joining seam member, with the first contoured body portion and the second contoured body portion being joined together using the joining seam member.