Pocket Handle Bend Tab Assembly to Reduce Fastener Count

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Solution Overview

Problem

The installation of pocket handles on dishwasher doors often requires multiple threaded fasteners, increasing manufacturing complexity, cost, and repair time due to the need for separate components and alignment during assembly and maintenance.

Innovation Solution

A pocket handle design that eliminates the use of separate fasteners by incorporating deformable bend tabs that engage with a flange to secure the handle to the door panel, allowing for installation without screws or additional components.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Strength

If threaded fasteners are used to secure the pocket handle to the door panel, then the handle is securely attached, but the number of parts increases and installation time increases

Engineering Contradiction:

Improveattachment strengthVSAvoidnumber of parts

Core Design Contradiction:

StrengthVSDevice complexity

Solution Approach 1:

The fastening function is merged into the handle structure itself through the bend tabs that are integral to the handle body. The tabs are formed from the same piece of material as the handle, eliminating the need for separate fasteners while maintaining secure attachment capability

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The separate fastener components are extracted from the assembly and replaced with self-contained bend tabs that are part of the handle structure, reducing part count while achieving the same fastening function

Inventive Principle:

Principle #2Taking out (Extraction)

2Strength

If threaded fasteners are used to secure the pocket handle, then secure attachment is achieved, but installation time and manufacturing cost increase

Engineering Contradiction:

Improveattachment strengthVSAvoidinstallation time

Core Design Contradiction:

StrengthVSLoss of time

Solution Approach 1:

The bend tabs are pre-formed with deformation zones that allow for quick installation. The tabs are designed to be bent into the engaged position during installation, eliminating the time-consuming process of threading and tightening multiple fasteners

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

The attachment function is combined into the handle structure itself through integral bend tabs, eliminating the need for separate fastening operations and reducing installation time

Inventive Principle:

Principle #5Merging (Combining)

3Strength

If multiple threaded fasteners are used, then the handle is securely mounted, but repair time and complexity increase

Engineering Contradiction:

Improvemounting securityVSAvoidrepair time

Core Design Contradiction:

StrengthVSEase of repair

Solution Approach 1:

Separate fastener components are removed from the assembly and replaced with self-contained bend tabs, simplifying the repair process to merely unbending and repositioning the tabs rather than dealing with multiple screws and fasteners

Inventive Principle:

Principle #2Taking out (Extraction)

Solution Approach 2:

The bend tabs can be easily deformed and repositioned during repair, allowing for quick disassembly and reassembly without specialized tools or multiple fastening operations

Inventive Principle:

Principle #34Discarding and recovering

4Strength

If separate fasteners are used for mounting the handle, then secure attachment is achieved, but manufacturing cost increases

Engineering Contradiction:

Improveattachment strengthVSAvoidmanufacturing cost

Core Design Contradiction:

StrengthVSEase of manufacture

Solution Approach 1:

The fastening function is merged into the handle structure through integral bend tabs, eliminating the need to source, inventory, and assemble multiple separate fastener components, thereby reducing manufacturing cost

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

Separate fastener components are extracted from the bill of materials and replaced with self-contained tabs formed from the handle material itself, reducing part count and manufacturing complexity

Inventive Principle:

Principle #2Taking out (Extraction)

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 solution simplifies the installation and repair process by reducing the number of required fasteners, lowering manufacturing costs and time, and facilitating easier handling and alignment during assembly and maintenance.

Implementation Method 1

The bend tabs are deformable into a second position where the plurality of bend tabs engage the flange to secure the pocket handle to the front panel

Methodology Applied

Scientific EffectDeformation: Deformation

Data Source

PatentUS12114826B2Pocket handle bend tab for an appliance

Publication Date: 2024.10.15 HAIER US APPLIANCE SOLUTIONS INC

AI summary

A household appliance includes a cabinet defining a chamber, a door assembly mounted to the cabinet to selectively restrict access to the chamber, the door assembly includes a front panel defining a handle cavity. The door assembly also includes a pocket handle received in the handle cavity, the pocket handle having a flange with a plurality of tab passages. A plurality of bend tabs are positioned around the handle cavity and received in a first position through the plurality of tab passages. The bend tabs are deformable into a second position where they engage the flange to secure the pocket handle to the front panel.