Ladder Rack Mounting Bracket for Vacuum-Sealed Appliance Panels
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Solution Overview
Problem
Existing appliance mounting systems face challenges in securely fastening ladder racks to mounting brackets within vacuum insulated appliances without compromising the vacuum seal, particularly in providing a reliable and cost-effective assembly method that maintains structural integrity and ease of assembly.
Innovation Solution
The proposed solution involves a mounting assembly with a self-clinching nut and coupling members that engage in an interference fit with the ladder rack, utilizing distal arms and coupling members that flare outward and inward to secure the ladder rack to the mounting bracket, allowing for both snap-fit and mechanical fastening, which aligns with the vacuum insulated structure's requirements.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If traditional fastening methods are used to secure the ladder rack to the mounting bracket, then the structural integrity is improved, but the vacuum seal is compromised
Solution Approach 1:
The mounting bracket acts as an intermediary component between the ladder rack and the appliance interior wall. It provides external fastening points (distal arms) that secure the ladder rack without penetrating the vacuum seal, while the coupling members provide internal engagement points that secure the rack from the non-vacuum side, thus maintaining vacuum integrity while achieving structural strength
Solution Approach 2:
The patent replaces traditional mechanical fastening methods that would penetrate the vacuum seal (screws, bolts through the wall) with a system using interference fits and friction-based coupling. The coupling members engage with the ladder rack through interference fit, and the distal arms provide external mechanical support without compromising the vacuum barrier
2Reliability
If a secure fastening system is implemented, then the reliability of the ladder rack attachment is improved, but the complexity of the assembly increases
Solution Approach 1:
The mounting bracket is segmented into distinct functional components: distal arms for external support and coupling members for internal engagement. This segmentation allows each component to perform its specific function optimally while keeping the overall design relatively simple and manageable
Solution Approach 2:
The coupling members are designed to engage with the ladder rack through interference fit, which is a self-aligning and self-securing mechanism. The flared geometry of the coupling members automatically guides the ladder rack into proper alignment and secures it through friction, eliminating the need for complex adjustment mechanisms or multiple fastening steps
3Strength
If traditional mounting methods are used, then the structural integrity is maintained, but the cost of manufacturing increases
Solution Approach 1:
The mounting bracket merges multiple functions into a single component: it provides external support through distal arms, internal engagement through coupling members, and structural connection to the appliance wall. This consolidation eliminates the need for multiple separate parts (brackets, screws, washers, etc.), reducing manufacturing complexity and cost while maintaining structural integrity
Solution Approach 2:
The patent uses interference fit as a design parameter, where the coupling members are sized to create a friction-based connection with the ladder rack. This approach eliminates the need for additional fasteners and reduces manufacturing steps, thereby lowering production costs while ensuring secure attachment
Data Source
AI summary
An appliance mounting assembly includes a mounting bracket with first and second distal arms that flare outward in opposing directions from an attachment body and couple to a panel. The mounting bracket includes a pair of coupling members that extend from the attachment body toward the panel surface and distal ends that curve inward toward one another. A self-clinching nut has an undercut, serrated clinching ring, and base. The undercut and the serrated clinching ring are disposed within an aperture defined by the attachment body. A ladder rack has first and second sides coupled via an attachment wall. The first and second sides define protrusions that engage the pair of coupling members in an interference fit. The attachment wall defines a receiving hole that aligns with the aperture. A threaded fastener extends through the receiving hole and engages the self-clinching nut to fasten the ladder rack to the mounting bracket.