Non-Encapsulated Glass Lid for Ball Drop-Resistant Washers
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Solution Overview
Problem
Vertical-axis, top-loading washing machines face manufacturing complexity and cost increases due to the need for encapsulated glass lids to pass the UL 746C ball drop test, limiting the adoption of transparent lids compared to horizontal-axis, front-loading machines.
Innovation Solution
A non-encapsulated glass lid assembly with a 4-6 mm thick glass panel, frit application, edge treatment, and heat or chemical strengthening, which allows the lid to pass the UL 746C ball drop test without additional edge reinforcement.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Illumination intensity
If a transparent glass lid is used in a top-loading washing machine, then the aesthetic appeal and viewing capability are improved, but the lid fails to pass the UL 746C ball drop test without encapsulation
Solution Approach 1:
The patent applies heat strengthening or chemical strengthening treatments to the glass panel, fundamentally changing the physical parameters of the glass to increase its strength. This allows the glass to withstand the ball drop test impact while remaining transparent and non-encapsulated, resolving the contradiction between transparency and impact resistance
Solution Approach 2:
The patent uses frit (a glass-based coating material) applied to the glass panel edges, creating a composite structure that combines the transparency of glass with the protective properties of frit. This composite approach provides edge protection and enhances impact resistance while maintaining the aesthetic appeal of a non-encapsulated transparent lid
2Reliability
If the glass lid edge is encapsulated to pass safety tests, then the impact resistance is improved, but the manufacturing complexity and cost increase
Solution Approach 1:
The patent extracts the encapsulation step from the manufacturing process, eliminating the need for separate edge encapsulation operations. By applying frit directly to the glass edges and using strengthening treatments, the design removes the complex encapsulation assembly while still achieving the required impact resistance
Solution Approach 2:
The patent merges multiple functions into the glass panel itself: the glass provides both the transparent viewing surface and the structural strength through heat/chemical strengthening. The frit application combines edge protection with aesthetic finishing, eliminating the need for separate encapsulation components and simplifying manufacturing
3Reliability
If the glass lid edge is encapsulated to pass safety tests, then the impact resistance is improved, but the manufacturing cost increases
Solution Approach 1:
The patent employs cost-effective solutions: frit is a relatively inexpensive material that can be applied directly to glass edges using standard coating techniques. Heat strengthening and chemical strengthening are established, scalable processes that add minimal cost compared to complex encapsulation assembly, making the overall solution more economical
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
Simplifies manufacturing and reduces costs by enabling the use of thinner glass lids that are both aesthetically appealing and impact-resistant, while maintaining compliance with safety standards, thus expanding the use of transparent lids in top-loading washing machines.
Implementation Method 1
a frit applied to the glass panel at least along the non-encapsulated portion
Implementation Method 2
at least one of a heat or chemical strengthening treatment applied to the glass panel
Implementation Method 3
at least one of a heat or chemical strengthening treatment applied to the glass panel
Data Source
AI summary
A vertical axis laundry treating appliance having a non-encapsulated lid comprising a single panel of glass that is able to pass the UL 746C ball drop test. Non-encapsulated glass lids according to embodiments of the disclosure simplify part and assembly complexity compared to encapsulated glass lids.