A bellows suitable for use in washing machines and the production method thereof
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Solution Overview
Problem
The existing methods for producing bellows for washing machines are laborious and expensive due to the need for different molds for various machine capacities, leading to increased production costs and time.
Innovation Solution
A method involving extrusion of an elastic strip through a mold, followed by cutting and connecting the ends to form a cylindrical structure suitable for different diameters, using a single mold, and incorporating bent portions for flexibility and durability, reduces production time and costs.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If the injection method is used to produce bellows, then the bellows can be manufactured with good structural integrity, but the production process becomes laborious and expensive due to requiring different molds for each washing machine capacity
Solution Approach 1:
The patent applies universality by using a single mold for producing bellows of different diameters. The mold is designed with a universal applicability that allows it to produce bellows suitable for various washing machine capacities, eliminating the need for multiple specialized molds while maintaining manufacturing precision
Solution Approach 2:
The patent employs parameter changes by modifying the extrusion process parameters rather than the mold itself to accommodate different bellows diameters. By changing extrusion parameters such as material flow rate, temperature, and pressure, the same mold can produce bellows with different dimensions, thereby reducing production complexity
2Manufacturing precision
If different molds are used for different washing machine capacities, then each bellows can be precisely fitted, but the production time and costs increase significantly
Solution Approach 1:
The patent implements universality by designing a single mold that can produce bellows for different washing machine capacities. This universal mold maintains fitting precision through adjustable parameters and versatile design, while dramatically improving production efficiency by eliminating the need to change molds for different product specifications
Solution Approach 2:
The patent applies preliminary action by pre-designing the mold with universal capabilities and pre-establishing the extrusion parameters for different bellows sizes. This preliminary preparation allows for quick production switches without requiring actual mold changes during manufacturing, thereby maintaining precision while boosting productivity
3Productivity
If the elastic strip is produced as a continuous sheet and then cut, then production time is decreased, but additional joining steps are required to form the cylindrical structure
Solution Approach 1:
The patent applies segmentation by dividing the continuous elastic strip into segments of desired length after extrusion. This segmentation allows for efficient production of multiple bellows from a single continuous extrusion, improving productivity while the subsequent joining of ends completes the cylindrical form with minimal additional complexity
4Strength
If the ends of the elastic strip are joined by welding, then the connection strength is increased, but the production process becomes more complex
Solution Approach 1:
The patent replaces mechanical joining methods with welding technology to join the ends of the elastic strip. This substitution provides superior connection strength through metallurgical bonding, and while welding adds some process complexity, it eliminates the need for mechanical fasteners and assembly steps, ultimately simplifying the overall joining process
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 enables quick, cost-effective production of symmetrical, flexible bellows suitable for various washing machine diameters, minimizing defects and operational stress, while reducing mold changes and production time.
Implementation Method 1
obtaining an elastic strip (9) by extruding the base material as a continuous strip by the extrusion method
Implementation Method 2
passing an extrudable base material through an extrusion mold and connecting the two ends of an elastic strip that is formed as a long line with a cross section that fits the form of the mold
Implementation Method 3
The elastic strip that exits the extrusion mold as a continuous sheet is cut in desired lengths so as to match the diameter of the opening and the peripheral bellows is obtained by joining the short edges of the elastic strip in a surface-to-surface manner by means of a suitable connection method such as riveting, welding, etc.
Implementation Method 4
the two edges of the elastic strip are welded to each other by butt-welding
Implementation Method 5
the bellows produced from an elastic material has at least one bent portion remaining between a first edge section that is connected to the body so as to surround the loading port and a second edge section that is connected to the tub so as to surround the opening. Thus, the cylindrical bellows is enabled to be flexible in all directions and the tensile forces and the frictional forces acting on the bellows and especially on the connection region where the ends of the elastic strip are joined together are enabled to be substantially decreased
Data Source
Figure 1
Figure 2~3
Figure 4~5
AI summary
The present invention relates to a flexible bellows (11) that is suitable for use in a washing machine (1) and to the production method of said bellows (11).