Single-Blank Packaging Brace for Washing Machine Transit Constraint
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Solution Overview
Problem
Existing packaging solutions for washing machine appliances are complex and require multiple discrete pieces for assembly, making them difficult to use effectively in constraining the basket and tub relative to the cabinet during shipping, which can lead to damage during transit.
Innovation Solution
A flat blank is used to form a simple packaging brace that includes a bottom panel and side panels joined by seams, which can be folded to contact the cabinet opening and basket, providing a stable configuration without the need for additional parts or adhesives.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If multiple discrete pieces are used to construct the packaging brace, then the brace can provide adequate structural support to constrain the basket and tub, but the construction becomes complex and requires additional assembly steps
Solution Approach 1:
The patent combines multiple discrete pieces into a single integrated packaging brace structure. The flat blank is formed as one continuous piece that includes side panels, corner segments, and panel sections all connected together, eliminating the need for separate components and their associated assembly steps while maintaining the structural support function
2Reliability
If multiple discrete pieces with interlocking features are used, then the brace can be assembled to constrain moving parts, but additional assembly steps such as interlocking and applying adhesives are required
Solution Approach 1:
The packaging brace is formed as a single integrated piece where all structural elements are pre-connected in the flat blank. The side panels, corner segments, and panel sections are all part of the same continuous structure, eliminating the need for interlocking operations and adhesive application while ensuring reliable constraint of the basket and tub
3Device complexity
If a single flat blank is folded to form the packaging brace, then the construction is simple and requires no additional parts or adhesives, but the seams must be precisely aligned and contacted to define corners
Solution Approach 1:
The flat blank is pre-formed with specific geometric features including corner segments with seams positioned at predetermined locations. The side panels and panel sections are pre-configured with dimensions and angles that guide the folding process, ensuring that when folded, the seams naturally align and contact to define the corner positions of the three-dimensional structure
Data Source
AI summary
A method of forming a packaging brace for a washing machine appliance includes providing a flat blank. The method also includes folding a left side panel and a right side panel of the flat blank inwards towards each other. The method further includes positioning a bottom panel of the blank above an opening in a cabinet of the washing machine and inserting the bottom panel into a basket of the washing machine through the opening whereby a contoured profile of the opening urges the blank to fold and form a packaging brace for the washing machine appliance.