Molded pulp external packing member for a dishwasher appliance
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Solution Overview
Problem
Conventional dishwasher appliance packaging materials, often made from non-recyclable foams, are susceptible to damage during transportation and have limited usability and shape flexibility, posing challenges in protecting sensitive components like the latch assembly.
Innovation Solution
A recyclable molded pulp external pack member with channels and channels formed into its base panel, providing structural support and protection to dishwasher components during transit, using materials like recycled paperboard.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If non-recyclable foam materials are used for packaging, then protection capability is improved, but environmental sustainability deteriorates
Solution Approach 1:
The patent changes the material parameter from conventional non-recyclable foam to molded pulp material, transforming the packaging material's environmental properties while maintaining protective capabilities through structural design
Solution Approach 2:
The patent uses molded pulp material, which is a composite material made from recycled fibers, to create packaging that combines protective strength with environmental sustainability and recyclability
2Ease of manufacture
If conventional padding materials are used, then ease of manufacture is improved, but shape flexibility deteriorates
Solution Approach 1:
The packaging structure is divided into multiple functional zones including recesses, channels, and protrusions that can be independently designed to fit specific appliance components, providing shape flexibility while maintaining manufacturing efficiency through molded pulp forming processes
Solution Approach 2:
Different regions of the packaging member have different structural properties - some areas provide cushioning, others provide rigid support, and specific zones are designed to accommodate particular components like door assemblies or control panels, optimizing protection for each component type
3Reliability
If narrow latch assembly windows are protected with conventional securing features, then reliability is improved, but device complexity deteriorates
Solution Approach 1:
Multiple protective functions are merged into a single integrated molded pulp structure that provides cushioning, rigid support, and component-specific accommodation zones, eliminating the need for separate padding materials and securing features
Solution Approach 2:
The packaging member serves multiple functions simultaneously - it protects the latch assembly windows, supports door assemblies, cushions control panels, and provides structural rigidity, all within a single component design
Data Source
AI summary
An external pack member for a dishwasher appliance, the external pack member includes a base panel extending along the lateral direction and the transverse direction; a first channel formed downward into a top surface of the base panel along the vertical direction and extending along the lateral direction; and a second channel formed upward along the vertical direction into a bottom surface of the base panel and extending along the lateral direction, wherein the external pack member is formed from a recyclable molded pulp material.