Sheet Metal Corner Hem Interlock Without Secondary Joining
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Solution Overview
Problem
The existing panel assembly methods require expensive and time-consuming secondary joining processes, such as welding or mechanical fastening, to form sheet-metal panel assemblies, increasing the cost and manufacturing time of components like oven appliance doors.
Innovation Solution
A panel assembly design that includes a main panel and side panels with integrally formed tabs and extensions, allowing for self-interlocking without the need for secondary joining, where the tabs and extensions are bent to form a notch and overlap, securing the panels without additional fasteners.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If secondary joining processes such as welding or mechanical fastening are used to assemble sheet-metal panel assemblies, then the structural integrity and strength of the assembly is improved, but the manufacturing time and cost increase significantly
Solution Approach 1:
The patent merges the panel assembly process by integrating interlocking features directly into the panel structure itself, eliminating the need for separate secondary joining processes. The tabs with notches and extensions are formed as integral parts of the panels during the initial forming operation, combining structure creation and joining functions into a single process step.
Solution Approach 2:
The panel assembly system employs self-interlocking features where tabs on one panel engage with notches and extensions on adjacent panels automatically during assembly. The structural integrity is achieved through the self-service mechanism of the interlocking geometry rather than requiring external joining operations, thus reducing manufacturing time while maintaining strength.
2Reliability
If secondary joining processes are used to form panel assemblies, then the reliability of the joint connection is improved, but the device complexity and manufacturing cost increase
Solution Approach 1:
The patent extracts the joining function from separate secondary processes and integrates it directly into the panel geometry. The interlocking features (tabs, notches, extensions) are built into the panels themselves during forming, removing the need for external fasteners or joining equipment and simplifying the overall assembly process while maintaining reliable connections.
Solution Approach 2:
The panel design incorporates segmented interlocking features with tabs containing notches and extensions that divide the joining function into discrete geometric elements. These segmented features engage with corresponding elements on adjacent panels, providing reliable connections through modular geometry rather than requiring complex unified joining processes.
3Ease of manufacture
If traditional panel assembly methods with separate joining processes are used, then the ease of manufacture of individual panels is maintained, but the overall productivity of panel assembly decreases
Solution Approach 1:
The interlocking features (tabs with notches and extensions) are formed as integral parts of the panels during the initial forming operation, before assembly takes place. This preliminary action of pre-forming the joining features eliminates the need for separate joining steps during assembly, thereby maintaining ease of panel fabrication while significantly improving overall assembly productivity.
Data Source
AI summary
A panel assembly including a main panel, a first side panel, a second side panel, a first tab, a second tab, and an extension. The first tab defines a planar notch into which the extension is positioned to restrict movement of the first side panel and the second side panel.