Method of manufacturing a multi-component part of a household and/or cooking appliance
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Solution Overview
Problem
The challenge in manufacturing multi-component parts for household appliances, such as cooking ovens, is the complexity of applying an anticorrosive enamel layer, especially when integrating components like waveguide systems, which can be damaged by welding or brazing processes, and requires efficient methods to avoid enamel degradation.
Innovation Solution
A method involving a multi-layered structure with a gap between metal layers for bonding, allowing for substance-to-substance joints like welding or brazing without directly exposing the anticorrosive layer to bonding energy, thereby preventing damage and facilitating the coating process by applying the enamel to smaller, less complex components before assembly.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If components are assembled first and then coated with enamel, then the coating process becomes more complex and time-consuming, but the structural integrity and functionality of the appliance are maintained
Solution Approach 1:
The patent applies preliminary action by coating the cavity components with enamel before assembling the waveguide system and other functional components. This allows the enamel to be applied to smaller, simpler surfaces that are easier to coat uniformly, avoiding the complexity of coating assembled multi-component structures. The coating is performed on the cavity walls and door separately before final assembly, significantly simplifying the coating process.
2Reliability
If waveguide system is coated with enamel before assembly, then the coating provides better corrosion protection, but the welding or brazing process may damage the enamel layer
Solution Approach 1:
The patent applies local quality by creating a multi-layer structure where the cavity wall has an enamel coating on its inner surface for corrosion protection, while the bonding area on the outer surface consists of bare metal layers without enamel. This allows the enamel to provide corrosion protection where needed (inner cavity surface) while leaving the bonding areas exposed for reliable welding or brazing of the waveguide system without enamel damage.
Solution Approach 2:
The patent segments the cavity wall structure into distinct functional zones: an enameled inner surface for corrosion protection and ease of cleaning, and a bare metal outer bonding area for reliable substance-to-substance joints. The multi-layer construction separates the enamel coating from the bonding interface, allowing each zone to perform its specific function without interfering with the other.
3Reliability
If a multi-layered structure with gap is used for bonding, then the enamel layer is protected from bonding energy, but the structural complexity increases
Solution Approach 1:
The patent segments the bonding structure into multiple metal layers with gaps between them, creating a multi-layered bonding area. This segmentation allows the bonding energy to be applied to the metal layers without directly affecting the enamel coating on the cavity wall, as the gap acts as a thermal and energy barrier. The multi-layer structure protects the enamel while maintaining bonding effectiveness.
4Reliability
If enamel is applied to the entire cavity including bonding areas, then complete corrosion protection is achieved, but the bonding process becomes difficult and may damage the enamel
Solution Approach 1:
The patent applies local quality by selectively coating only specific areas of the cavity with enamel - specifically the inner surfaces that require corrosion protection and ease of cleaning - while leaving the bonding areas on the outer surfaces as bare metal. This selective coating approach achieves adequate corrosion protection for the functional surfaces without creating the manufacturing difficulties that would arise from coating the entire cavity including bonding zones.
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
This method enables the efficient manufacture of multi-component parts with an anticorrosive layer, ensuring the enamel remains intact and simplifies the coating process by applying it to smaller components before assembly, reducing thermal conductivity and potential damage during bonding.
Implementation Method 1
reducing thermal conductivity and potential damage during bonding
Data Source
AI summary
The underlying invention is in particular related to a method of manufacturing a multi-component part (1) of a cooking and/or household and/or kitchen appliance. the multi-component part (1) comprising a first component (2) and a second component (3) wherein the first and second components (2.3) are interconnected by a substance-to-substance bond (4).