Refrigerator Casing Mitered Joint Using Plastically Deformed Tabs

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Solution Overview

Problem

Mitered joints in refrigerator casings require costly post-process painting and can be damaged by rubbing, necessitating expensive repair processes, while traditional welding is avoided in pre-painted metal sheets.

Innovation Solution

The use of plastically deformed or folded tabs on the front flanges to connect at a mitered joint, eliminating the need for welding and reducing paint damage, thereby minimizing additional painting requirements.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Strength

If mitered joints are welded, then the joint strength is improved, but post-process painting is required which increases manufacturing cost and time

Engineering Contradiction:

Improvejoint strengthVSAvoidmanufacturing cost and time

Core Design Contradiction:

StrengthVSEase of manufacture

Solution Approach 1:

The patent replaces the welding process (thermal/mechanical system) with a mechanical interlocking system using tabs that fold and engage with slots. This substitution eliminates the need for post-weld painting while maintaining joint strength, directly resolving the contradiction between joint strength and manufacturing complexity.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

2Ease of manufacture

If pre-painted metal sheets are used without welding, then manufacturing cost and time are reduced, but rubbing between front flanges damages the paint

Engineering Contradiction:

Improvemanufacturing cost and timeVSAvoidpaint damage

Core Design Contradiction:

Ease of manufactureVSObject-affected harmful factors

Solution Approach 1:

The patent introduces tabs as intermediary elements that engage with slots to connect front flanges. These tabs act as mediators that prevent direct rubbing between painted surfaces while still achieving secure connection, thus preserving the paint finish on pre-painted metal sheets.

Inventive Principle:

Principle #24Intermediary (Mediator)

Solution Approach 2:

The connection mechanism is segmented into separate components: tabs on one flange and corresponding slots on the other flange. This segmentation allows the painted surfaces to remain separated during assembly, preventing paint damage while maintaining ease of manufacture with pre-painted sheets.

Inventive Principle:

Principle #1Segmentation

3Ease of manufacture

If mitered joints are connected with tabs that are plastically deformed, then the need for welding and painting is eliminated, but the complexity of the joint design increases

Engineering Contradiction:

Improveelimination of welding and paintingVSAvoidjoint design complexity

Core Design Contradiction:

Ease of manufactureVSDevice complexity

Solution Approach 1:

The patent utilizes plastic deformation as a parameter change in the tab material during assembly. The tabs are deformed from their initial state to engage with the slots, creating a permanent mechanical connection. This parameter change simplifies the overall manufacturing process by eliminating welding and painting steps.

Inventive Principle:

Principle #35Parameter changes

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 effectively forms a strong and aesthetically appealing mitered joint without the need for welding or costly repainting, reducing manufacturing costs and improving the cosmetic appearance.

Implementation Method 1

The tabs of the first and second front flanges are plastically deformed together at the mitered joint

Methodology Applied

Scientific EffectPlastic deformation: Plasticity

Data Source

PatentUS10704824B1Refrigerator casing with a mitered front corner joint

Publication Date: 2020.07.07 HAIER US APPLIANCE SOLUTIONS INC

AI summary

A refrigerator appliance includes a cabinet that defines a chilled chamber. The cabinet has an outer casing with a first front flange and a second front flange. The first and second front flanges are connected at a mitered joint. Each of the first and second front flanges has a tab extending into the outer casing. The tabs of the first and second front flanges are plastically deformed together at the mitered joint.