Injection-Molded Cutlery Drawer with Overmolded Functional Elements
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Solution Overview
Problem
Existing crockery baskets and cutlery drawers in dishwashers face limitations in functional integration due to the combination of plastic inserts and wire support frames, leading to complex production, high soiling tendencies, and the need for additional add-on parts.
Innovation Solution
A crockery basket with a plastic support frame designed as an injection-molded part that embeds functional elements, such as stainless steel components and wire reinforcement, allowing for increased functional integration and simplified assembly while reducing soiling risks.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If a wire support frame with plastic inserts is used, then the structure provides sufficient stability, but functional integration is limited and additional add-on parts are required
Solution Approach 1:
The patent merges the support frame and functional elements into a single integrated plastic component. The support frame is designed as an injection-molded part that incorporates functional elements directly, eliminating the need for separate wire frames and add-on parts. This integration resolves the contradiction by providing both structural stability and functional versatility through a unified design.
Solution Approach 2:
The plastic support frame is designed to perform multiple functions simultaneously - providing structural support, accommodating functional elements, and enabling various dish rack configurations. The frame includes integrated features for roller mounting, dish positioning, and structural reinforcement, all within a single component that serves universal purposes.
2Adaptability or versatility
If add-on parts are attached to the wire support frame, then additional functions are provided, but production and assembly become complex and soiling tendency increases
Solution Approach 1:
The patent combines multiple components into a single injection-molded plastic support frame that includes all functional elements integrated within its structure. This eliminates the need for separate add-on parts and simplifies both production and assembly processes, as the entire assembly can be manufactured in one piece or as a unified component set.
Solution Approach 2:
The patent extracts the wire frame from the design and replaces it entirely with a plastic support frame that incorporates all necessary functional elements. This extraction eliminates the complexity associated with attaching add-on parts to wire frames, as the plastic frame is designed to include all functions directly within its structure.
3Adaptability or versatility
If add-on parts are attached to the wire support frame, then additional functions are provided, but the tendency to soiling increases due to protrusions and gaps
Solution Approach 1:
The patent merges the support frame and functional elements into a seamless integrated structure. The plastic support frame is designed with functional elements that are either embedded within or smoothly integrated into the frame body, eliminating protrusions and gaps where food particles and water could accumulate. This creates a smooth, easy-to-clean surface.
Solution Approach 2:
The patent applies different material properties and surface characteristics to different areas of the support frame to optimize both functionality and cleanliness. The plastic material is selected for its smooth, non-porous surface that resists soiling, while local structural variations provide the necessary functional integration without creating cleaning problems.
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
The solution enhances production and assembly efficiency, reduces soiling, and increases the basket's strength and rigidity, enabling the absorption of torsional loads and providing greater design flexibility without the need for additional parts.
Implementation Method 1
a support frame which consists of plastic and is designed as an injection molded part
Implementation Method 2
a functional element arranged on the support frame is embedded at least in sections by overmolding in the plastic of the support frame
Data Source
Figure 1
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AI summary
The invention relates to a crockery basket, in particular a cutlery drawer, for a dishwasher, having a support frame (2) and an insert carried by it for holding crockery, in particular items of cutlery, and having a functional element (22) arranged on the support frame, the support frame (2) being made of consists of plastic and is designed as an injection molded part, the functional element (22) being embedded at least in sections by overmolding in the plastic of the support frame (2).