Integrally Formed Insert Assembly for Gap Finishing Without Welding
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Solution Overview
Problem
Conventional insert assemblies for finishing gap regions in electric home appliances are costly, time-consuming, and require additional assembly processes, often exposing sharp surfaces and compromising safety due to incomplete bending of steel sheets during manufacturing.
Innovation Solution
An integrally formed insert assembly with a body unit, an insert unit, and a hook unit that securely fits into the gap region, featuring a hook unit with elasticity and a wedge-shaped design to prevent separation and seal the gap, reducing production time and costs by eliminating the need for additional assembly steps.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a welding process is performed to finish the gap region, then the gap region is sealed and safety is improved, but production cost increases and additional polishing is required
Solution Approach 1:
The patent uses a disposable insert component that is inserted into the gap region to seal it, replacing the need for expensive welding processes. The insert is a simple, inexpensive component that can be easily manufactured and installed, providing the same safety function without the high cost and additional polishing requirements of welding
Solution Approach 2:
The patent replaces the welding process (thermal/mechanical system) with a simple mechanical insertion of the insert component. This substitution eliminates the need for complex welding equipment, skilled welders, and subsequent polishing operations, significantly reducing production cost while maintaining the gap-sealing function
2Reliability
If a conventional insert assembly with wedge and supporter is used, then the gap region is finished, but production time increases and production cost increases due to multiple components and auxiliary assembly lines
Solution Approach 1:
The patent merges the wedge and supporter components into a single integrated insert component. This unified design eliminates the need for separate assembly operations and auxiliary assembly lines, reducing production time while maintaining the gap-finishing function. The single component can be installed in one straightforward operation rather than requiring multiple assembly steps
3Reliability
If a conventional insert assembly with multiple components is used, then the gap region is finished, but device complexity increases and assembly process becomes complicated
Solution Approach 1:
The patent combines multiple components (wedge and supporter) into a single integrated insert component, dramatically simplifying the assembly process. The single component design eliminates the need for complex multi-step assembly procedures and reduces the number of parts that need to be managed, stored, and installed, making the overall process much simpler and more reliable
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 insert assembly effectively seals the gap region, enhances safety by preventing sharp surface exposure, and improves the external design of appliances, while reducing production time and costs by simplifying the assembly process and preventing moisture and foreign substance ingress.
Implementation Method 1
the hook unit (430) extended a preset distance from the insert unit (420) toward the body unit (410)... The hook unit may be formed of a material having elasticity.
Data Source
AI summary
An insert assembly inserted in a gap region provided in a panel to fill the gap region, the insert assembly including a body unit covering the gap region not to be exposed to the outside, an insert unit extended from the body unit and inserted in the gap region, and a hook unit extended a preset distance from the insert unit toward the body unit, the hook unit comprising one end connected to the insert unit and the other end provided as a free end, wherein the body unit, the insert unit and the hook unit are integrally formed with each other as one body.