Laundry treating appliance door assembly
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Solution Overview
Problem
Conventional laundry appliance door assemblies require multiple mechanical fasteners for assembly, which can be aesthetically unpleasing and complicate the assembly process, making it difficult to achieve a clean and seamless design.
Innovation Solution
The use of an adhesively bonded assembly process for a laundry treating appliance door, where an inner door frame is covered by an intermediate door frame and an outer screen door, with mechanical fasteners hidden from view, and a touch film with an integrated flexible printed circuit board is used to control the user interface controller, eliminating visible fasteners and simplifying assembly.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If multiple mechanical fasteners are used to assemble the door assembly, then the structural strength and reliability are improved, but the aesthetic appearance deteriorates due to visible fasteners and the assembly complexity increases
Solution Approach 1:
The patent extracts the mechanical fasteners from the visible exterior surfaces of the door assembly. Fasteners are positioned only on the inner door frame and intermediate door frame, which are then covered by outer door screens and trim pieces. This extraction maintains structural strength while eliminating aesthetic defects from visible fasteners.
Solution Approach 2:
The door assembly employs a nested structure where the inner door frame is covered by the intermediate door frame, which is in turn covered by the outer door screen. This multi-layer nesting allows fasteners to be concealed within inner layers while maintaining structural integrity through each successive layer.
2Reliability
If multiple mechanical fasteners are used to assemble the door assembly, then the structural reliability is improved, but the assembly process complexity and time consumption increase
Solution Approach 1:
The door assembly is segmented into distinct functional modules: inner door frame assembly, intermediate door frame assembly, and outer door screen assembly. Each module can be pre-assembled and tested independently, then integrated together. This segmentation reduces overall assembly complexity while maintaining structural reliability through modular construction.
3Shape
If multiple layers of door assembly are used to hide fasteners, then the aesthetic appearance is improved, but the device complexity increases
Solution Approach 1:
The intermediate door frame serves multiple functions: it provides structural support, acts as a mounting surface for the outer door screen, and serves as a cover for the inner door frame fasteners. This multi-functionality reduces the need for additional separate components, thereby limiting complexity increase despite the multi-layer design.
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 results in a seamless and aesthetically pleasing door assembly with minimal visible fasteners, enhancing the user experience and simplifying the assembly process while maintaining functionality.
Implementation Method 1
the intermediate door frame being adhered to a front of the inner door frame
Implementation Method 2
A hinge cover is adhesively bonded to the inner door frame to cover the one or more mechanical fasteners
Implementation Method 3
The touch film is adhered to the interior surface of the outer screen door
Data Source
AI summary
A laundry treating appliance having a door assembly with an inner door frame. One or more mechanical fasteners extending the inner door frame so secure one of a hinge or handle to the door frame. Hinge and handle covers are adhesively bonded to the inner door frame to cover the one or more mechanical fasteners. A user interface controller is affixed to the door frame through an aperture in an inner door subassembly. A touch film having an integrated flexible printed circuit board with touch buttons is in communication with and configured to control the user interface controller. The touch film is adhered to the interior surface of the outer screen door.