Variable-Density Foam Panel for Dishwasher Door Noise Control
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Solution Overview
Problem
Home appliances, such as dishwashers, face challenges in noise reduction and energy efficiency due to complex assemblies and the need for multiple materials, which can increase manufacturing costs and complexity.
Innovation Solution
A foam panel with areas of differing densities is used in the door assembly of dishwashers, incorporating compressed and uncompressed regions to provide sound absorption, thermal insulation, and structural features like ribs for wiring attachments, simplifying assembly and reducing part counts.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Object-affected harmful factors
If multiple materials and complex assemblies are used in dishwasher door assembly, then noise reduction and energy efficiency are improved, but manufacturing cost and complexity increase
Solution Approach 1:
The patent combines multiple functions (sound absorption, thermal insulation, structural support, wiring integration) into a single foam panel component. This merging eliminates the need for separate assemblies of multiple materials, thereby reducing manufacturing complexity while maintaining noise reduction and energy efficiency benefits.
Solution Approach 2:
The foam panel is designed to perform multiple functions simultaneously: it provides acoustic insulation through compressed and uncompressed areas, thermal insulation through the door cavity, structural support through integrated ribs, and wiring attachment through molded features. This multi-functionality reduces the overall device complexity by replacing multiple specialized components with one universal component.
2Loss of energy
If multiple materials and complex assemblies are used in dishwasher door assembly, then energy efficiency is improved, but manufacturing cost increases
Solution Approach 1:
The patent merges thermal insulation, sound absorption, and structural functions into a single foam panel that can be molded as one piece. This eliminates the need to assemble multiple separate materials, thereby reducing labor and assembly costs while maintaining energy efficiency through the insulated door cavity.
Solution Approach 2:
The foam panel utilizes composite material properties by incorporating both compressed and uncompressed areas within a single material structure. This allows the panel to provide varying levels of insulation and structural support in different regions, achieving energy efficiency without requiring multiple different materials and the associated manufacturing complexity.
3Device complexity
If integrated wiring attachments are formed in the foam panel, then part count is reduced, but manufacturing precision requirements increase
Solution Approach 1:
The wiring attachments are pre-formed as integral ribs and features during the foam panel molding process. This preliminary action of creating attachment points before final assembly simplifies the overall manufacturing process by eliminating separate wiring installation steps, and the molding process inherently provides the necessary precision for these integrated features.
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
The foam panel effectively reduces noise, enhances energy efficiency by providing thermal insulation, and simplifies manufacturing by integrating multiple functions into a single component, leading to cost savings and improved appliance performance.
Implementation Method 1
The foam panel effectively reduces noise
Implementation Method 2
enhances energy efficiency by providing thermal insulation
Data Source
AI summary
A foam panel for use in a dish treating appliance having a door. The foam panel comprises areas of differing densities. The foam panel comprises uncompressed and compressed areas to form at least some of the areas of differing densities. The foam panel also comprising at least one wiring attachment provided with the foam panel wherein the wiring attachment comprises at least one rib formed in the foam panel.