Force Distributor Structure for Low-Material Appliance Shipping Protection
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Solution Overview
Problem
Existing household appliance force distributors are costly due to material expenses and require screws for attachment, which increases production costs and complexity.
Innovation Solution
The use of force distributors with cut-out sections that reduce material usage by up to 50% and employ snap-fit or press-fit mechanisms for attachment, eliminating the need for screws, formed through injection molding with thermoplastic materials like polystyrene or ABS.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Quantity of substance
If traditional force distributors are used without cut-out sections, then structural strength is maintained, but material costs increase by up to 50%
Solution Approach 1:
The force distributor is segmented by introducing cut-out sections that divide the block into distinct regions. These cut-outs create a lattice-like structure that maintains structural integrity while reducing material consumption by up to 50%. The segmentation allows the distributor to absorb forces through distributed stress points rather than requiring solid material throughout.
Solution Approach 2:
The force distributor employs a porous design with cut-out sections creating void spaces within the material structure. This porous configuration reduces overall material usage while maintaining sufficient strength to absorb shipping and handling forces. The porous structure allows force distribution through the remaining material walls and connection points.
2Reliability
If screws are used to attach force distributors to the frame, then secure attachment is achieved, but device complexity and production costs increase
Solution Approach 1:
The attachment mechanism is substituted from a mechanical screw-based system to an integrated snap-fit or press-fit system. The force distributor includes built-in attachment features such as protrusions that engage with corresponding recesses in the frame, eliminating the need for separate screws and reducing assembly complexity while maintaining secure attachment.
Solution Approach 2:
The attachment features are merged directly into the force distributor structure itself. The distributor is designed with integrated snap-fit or press-fit elements that become part of the main body, combining the force absorption function and attachment function into a single unified component rather than separate elements.
3Force
If solid block force distributors are used, then force absorption capacity is maximized, but material costs and weight increase
Solution Approach 1:
The solid block is segmented into a lattice structure with cut-out sections that maintain force absorption capacity through distributed stress points. The segmentation creates multiple load paths that collectively provide equivalent or superior force absorption compared to solid blocks while using up to 50% less material.
Solution Approach 2:
The force distributor utilizes a composite structure combining solid material regions with void spaces in a strategic arrangement. This composite configuration optimizes the ratio of material usage to force absorption capacity, achieving maximum protection with minimum material through carefully positioned solid sections that handle load bearing while empty spaces reduce overall material consumption.
Data Source
AI summary
A household appliance including a cabinet having a frame and one or more force distributors structured to absorb forces that the cabinet receives during shipping and handling. The one or more force distributors may include a block portion having cut-out sections throughout that lead to a generally flat planar bottom portion. To reduce material costs, the cut-out sections may include a surface area of greater than fifty percent of the total surface area of the one or more force distributors. The invention also includes a method for attaching the one or more force distributors to the household appliance.