Single-Piece Dishwasher Console Assembly to Eliminate Adhesive Bonding

Resolve Bottlenecks,
Find Innovative SolutionsGenerate Solutions

Solution Overview

Problem

The assembly process of dishwasher consoles requires the use of adhesive, increasing cost, time, and complexity due to the need to join multiple pieces, which complicates the integration of user interfaces and door components.

Innovation Solution

A single-piece console with a rotatable spacer is used, allowing for easier assembly by rotating the spacer from an initial to a fully installed position, and incorporating a U-shaped channel for secure attachment to the door panel, eliminating the need for adhesive.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Ease of manufacture

If multiple console pieces are joined using adhesive, then the console can be assembled, but the assembly process becomes more complex, time-consuming, and costly

Engineering Contradiction:

Improveassembly processVSAvoidconsole assembly structure

Core Design Contradiction:

Ease of manufactureVSDevice complexity

Solution Approach 1:

The patent merges multiple separate console pieces (front panel, top panel, and user interface assembly) into a single integrated console assembly. This single-piece console is mounted to the door panel as one unit, eliminating the need for adhesive bonds between multiple pieces and simplifying the assembly process while reducing complexity.

Inventive Principle:

Principle #5Merging (Combining)

2Productivity

If multiple console pieces are joined using adhesive, then the console can be assembled, but the assembly time increases

Engineering Contradiction:

Improveassembly speedVSAvoidassembly time

Core Design Contradiction:

ProductivityVSLoss of time

Solution Approach 1:

By combining multiple console pieces into a single pre-assembled console unit that mounts to the door panel in one operation, the patent eliminates the time-consuming steps of applying adhesive, positioning multiple pieces, and allowing bonding time. This single-mounting approach significantly reduces assembly time and increases productivity.

Inventive Principle:

Principle #5Merging (Combining)

3Ease of manufacture

If multiple console pieces are joined using adhesive, then the console can be assembled, but the manufacturing cost increases

Engineering Contradiction:

Improvemanufacturing processVSAvoidadhesive material and associated costs

Core Design Contradiction:

Ease of manufactureVSQuantity of substance

Solution Approach 1:

The patent eliminates the need for adhesive material by merging multiple console pieces into a single assembly that uses mechanical mounting features (such as mounting brackets or snap-fit connections) to attach to the door panel. This removes the cost of adhesive materials and the associated labor for adhesive application and bonding processes.

Inventive Principle:

Principle #5Merging (Combining)

Data Source

PatentUS10772480B2Dishwasher with door assembly

Publication Date: 2020.09.15 WHIRLPOOL CORP

AI summary

A household appliance includes a cabinet defining a chamber with an access opening. A door assembly is movably mounted to the cabinet to selectively open and close the access opening. The door assembly includes a door panel defining a front surface and side surfaces. A door panel flange extends inwardly from a rear edge of the side surface. A single-piece console defines a top surface, a front surface, and a rear attachment surface, the top surface substantially perpendicular to the front surface. A rotatable spacer is positioned between the rear attachment surface of the single-piece console and the door panel flange.