Water-using household appliance and method

Abstract

A water-using household appliance, in particular a household dishwashing machine, includes a wall which is made from a metal material, and a device which is made from a plastic material and fixedly connected to the wall by a laser weld.

Claims

1. A water-using household appliance, comprising: a wall made from a metal material, the wall having a surface structuring formed on at least a portion thereof; and a device made from a plastic material and fixedly connected to the portion of the wall having the surface structuring by a laser weld, wherein the surface structuring comprises a plurality of recesses arranged in a linear manner on the wall, wherein each of the plurality of recesses extends continuously over a substantial portion of the wall having the surface structuring, and wherein the plurality of recesses is characterized by a sawtooth appearance when viewed together in cross-section.

2. The water-using household appliance of claim 1, constructed in the form of a household dishwashing machine.

3. The water-using household appliance of claim 1, wherein the device includes a fastening flange which is fixedly connected to the wall by the laser weld.

4. The water-using household appliance of claim 1, wherein the device is a heat exchanger, a water inlet or a holder for a heating wire or a heating pipe.

5. The water-using household appliance of claim 1, wherein the device is a heat exchanger which comprises a storage portion and a functional portion connected to the storage portion.

6. The water-using household appliance of claim 1, wherein the metal material of the wall is chromium steel or chromium-nickel steel.

7. The water-using household appliance of claim 1, further comprising a washing container, said wall being part of the washing container.

8. A method of producing a water-using household appliance, said method comprising: producing a surface structuring on at least a portion of a wall made from a metal material of the water-using household appliance; arranging a device made from a plastic material on the wall, the device being disposed opposite to the portion of the wall having the surface structuring; and laser-welding the device to the wall, wherein the surface structuring comprises a plurality of recesses arranged in a linear manner on the wall, wherein each of the plurality of recesses extends continuously over a substantial portion of the wall having the surface structuring, and wherein the plurality of recesses is characterized by a sawtooth appearance when viewed together in cross-section.

9. The method of claim 8, wherein the surface structuring is carried out by using pulsed laser beams, such that laser light is emitted in chronologically defined periods.

10. The method of claim 8, further comprising laser-welding a fastening flange of the device to the wall.

11. The method of claim 8 for producing a household dishwashing machine.

12. The method of claim 8, wherein the recesses are arranged horizontally in orientation on the wall.

13. The water-using household appliance of claim 1, wherein the recesses are arranged horizontally in orientation on the wall.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

(1) In the figures:

(2) FIG. 1 shows a schematic perspective view of an embodiment of a household appliance;

(3) FIG. 2 shows a schematic sectional view of the household appliance according to FIG. 1;

(4) FIG. 3 shows the detailed view III according to FIG. 2;

(5) FIG. 4 shows the detailed view IV according to FIG. 3; and

(6) FIG. 5 shows a schematic block diagram of an embodiment of a method for producing the household appliance according to FIG. 1.

DETAILED DESCRIPTION OF EXEMPLARY EMBODIMENTS OF THE PRESENT INVENTION

(7) Elements which are the same or functionally the same have been provided with the same reference numerals in the figures unless indicated otherwise.

(8) FIG. 1 shows a schematic perspective view of an embodiment of a water-using household appliance 1. The household appliance 1 may be, for example, a household dishwashing machine, a household washing machine or any other household appliance, such as for example a coffee machine or the like. It is assumed hereinafter that the household appliance 1 is a household dishwashing machine. The household appliance 1 comprises a washing container 2 which is able to be closed by a door 3, in particular in a watertight manner. To this end, a sealing device may be provided between the door 3 and the washing container 2. The washing container 2 is preferably cuboidal. The washing container 2 may be arranged in a housing of the household appliance 1. The washing container 2 and the door 3 may form a washing chamber 4 for washing items to be washed.

(9) The door 3 is shown in FIG. 1 in its open position. The door 3 may be opened or closed by pivoting about a pivot axis 5 provided at a lower end of the door 3. A loading opening 6 of the washing container 2 may be closed or opened by means of the door 3. The washing container 2 has a plurality of walls 7 to 11. The washing container 2 preferably comprises a first wall 7, in particular a base, a second wall 8 arranged opposite the first wall 7, in particular a cover, a third wall 9 arranged opposite the closed door 3, in particular a rear wall, a fourth wall 10, in particular a first side wall, and a fifth wall 11 arranged opposite the fourth wall 10, in particular a second side wall.

(10) The first wall 7, the second wall 8, the third wall 9, the fourth wall 10 and the fifth wall 11 may be made, for example, from a stainless steel plate. For example, a rust-free stainless steel with the material identification number 1.4301, 1.4310, 1.4510 or 1.4016 is suitable for the material. Alternatively, the first wall 7 may be made from a plastic material, for example. The washing container 2 may be arranged on a base carrier, not shown. The base carrier is preferably a plastic component. In particular, the base carrier may be a plastic injection-molded component.

(11) The household appliance 1 also has at least one receiver for items to be washed 12 to 14. Preferably, a plurality of receivers for items to be washed 12 to 14, for example three, may be provided, wherein the receiver for items to be washed 12 may be a lower receiver for items to be washed or a lower basket, the receiver for items to be washed 13 may be an upper receiver for items to be washed or an upper basket and the receiver for items to be washed 14 may be a cutlery drawer. As FIG. 1 further shows, the receivers for items to be washed 12 to 14 are arranged superimposed in the washing container 2. Each receiver for items to be washed 12 to 14 is optionally displaceable into or out of said washing container 2. In particular, each receiver for items to be washed 12 to 14 is able to be inserted in an insertion direction E (arrow) into the washing container 2 and withdrawn counter to the insertion direction E (arrow) in a withdrawal direction A (arrow) out of the washing container 2.

(12) FIG. 2 shows a schematic sectional view of the household appliance 1. The household appliance 1 comprises a device 15 which may be provided on one of the walls 7 to 11. Preferably the device 15 is water-using. Thus the device 15 may also be denoted as a water-using device. Examples of water-using devices 15 are a heat exchanger, a water inlet, a water outlet, a pump sump or the like. However, the device 15 may also not use any water. In this case, the device 15 may be a holder for a heating wire or a heating pipe, for example. The device 15 may be configured as a half-shell, for example, heating wires and/or heating pipes being able to be snapped or clipped therein. However, it is assumed hereinafter that the device 15 is water-using.

(13) Preferably, the device 15 is provided on the fourth wall 10 or on the fifth wall 11. Moreover, the device 15 may also be provided on the third wall 9 or on the second wall 8. A plurality of devices 15 may also be provided. In FIG. 2, however, only one device 15 which is provided on the fifth wall 11 is shown.

(14) As mentioned above, the device 15 may be, for example, a heat exchanger or a water inlet. If the device 15 is a heat exchanger, this device may comprise a storage portion 16 and a functional portion 17. The storage portion 16 and the functional portion 17 may be components which are made separately from one another and which are fixedly connected together. Alternatively, the storage portion 16 and the functional portion 17 may also be configured integrally from the same material.

(15) The storage portion 16 is designed to store water and/or washing liquor. The functional portion 17 may comprise, for example, channels, valves, different systems or the like. The device 15 may be designed to store energy, in particular heat energy, for example in the form of heated water. This heat energy may be dissipated to the washing container 2. Conversely, energy may also be transferred from the washing container 2 to the device 15.

(16) The device 15 and, in particular, the storage portion 16 are preferably made from a plastic material. For example, polypropylene (PP), in particular a natural PP, a PP filled with a bulking agent, such as for example talc, for example PP talc 20 (PPTD20) or for example PP talc 30 (PPTD30), acrylonitrile-butadiene-styrene copolymer (ABS), polymethyl methacrylate (PMMA), polyvinylchloride (PVC), polyoxymethylene (POM), polyamide (PA), in particular glass fiber-filled polyamide, such as for example PA 6.6 GF 20 or PA 6.6 GF 30, or a thermoplastic elastomer (TPE) are suitable as the plastic material. The device 15 may also be made from different plastic materials. Moreover, the device 15 may also be made at least partially from a metal material. For example, a rust-free stainless steel with the material identification number 1.4301, 1.4310, 1.4510 or 1.4016 is suitable as the metal material.

(17) The storage portion 16 is configured in the form of a half-shell or trough which is configured to be open in the direction of the fifth wall 11. For connecting the storage portion 16 to the fifth wall 11 the device 15 comprises a fastening flange 18 which preferably entirely surrounds the storage portion 16 and, in particular, the device 15. The fastening flange 18 may have a width of approximately 5 to 20 mm.

(18) The fastening flange 18 is entirely made from a plastic material. The device 15 and, in particular, the storage portion 16 are connected in a fixed and watertight manner to the fifth wall 11 by means of laser weld 19 (FIG. 3). The device 15 and, in particular, the storage portion 16 thus enclose with the fifth wall 11 a liquid chamber 20. In other words, the liquid chamber 20 is only separated from the washing chamber 4 by the fifth wall 11, i.e. only by the metal material of the fifth wall 11. As a result, a particularly good heat transfer is ensured from the liquid chamber 20 to the washing chamber 4 and vice-versa. As a result, optimal diffusion ratios between the liquid chamber 20 and the washing chamber 4 may be achieved. Thus, the energy balance of the household appliance 1 is significantly improved in comparison with an arrangement in which a further plastic layer is provided between the liquid chamber 20 and the fifth wall 11.

(19) The functional portion 17 comprises a half-shell made from a plastic material which contains the aforementioned channels, valves and/or further systems. The functional portion 17 may be seal-welded by means of a film and a laser welding method. In this case, the use of the film also improves the diffusion conditions and thus the energy balance of the household appliance 1.

(20) The aforementioned advantages may also be utilized if the device 15 is a water inlet. The device 15 may also be designed as a composite component in which initially the functional portion 17 is seal-welded by means of the aforementioned film and then the storage portion 16 is directly joined to the fifth wall 11 by means of the laser welding method, in particular by means of a short-pulse laser.

(21) The washing container 2 and, in particular, the fifth wall 11 are made from a chromium steel or chromium-nickel steel. In particular, the fifth wall 11 is a thin plate. Thin plates are plates which have a thickness of less than 3 mm. In order to achieve a reliable and permanent connection of the fastening flange 18 to the fifth wall 11, the fifth wall 11 is provided with a surface structuring 21 in the region of the laser weld 19 (FIG. 3 and FIG. 4). The surface structuring 21 is introduced, for example by means of a nano-pulsed laser, into an outer face 22 of the fifth wall 11 remote from the washing chamber 4. The depth of the surface structuring 21 in this case is selected such that by the use of inert gas on an inner face 23 of the fifth wall 11 no oxidation dyes are present. The surface structuring 21 serves firstly for increasing the surface of the outer face 22 and the surface structuring 21 preferably also forms undercuts, the molten plastic material of the fastening flange 18 flowing therein and being positively connected to the undercuts.

(22) The surface structuring 21 may comprise a plurality of recesses 24 arranged in a linear manner, in FIG. 3 and FIG. 4 however only two being provided with a reference numeral. The recesses 24 may be arranged horizontally in the orientation of FIG. 3 and FIG. 4. The recesses 24, however, may also be positioned vertically or obliquely. In contrast to the view in FIG. 3 and FIG. 4 the recesses 24 may also have a curved, circular or any other geometry. The surface structuring 21 may also comprise recesses 24 arranged in the manner of a chessboard or in the shape of a matrix with variable orientation. As a result, the connection of the fastening flange 18 to the surface structuring 21 may be further improved.

(23) For example, the materials 1.4301, 1.4310, 1.4510 or 1.4016 may be used for the fifth wall 11 but also for the other walls 7 to 10. The recesses 24 of the surface structuring 21, for example, may have a depth of 10 to 100 μm, preferably of 15 to 90 μm, in particular of 20 to 80 μm. Raised portions which are produced by the material of the fifth wall 11 being melted around the recesses and being ejected from the recesses 24 may be formed to the side along the recesses 24.

(24) FIG. 5 shows a schematic block diagram of a method for producing the household appliance 1. In a step S1 the washing container 2 and, in particular, one of the walls 7 to 11 of the washing container 2 is provided. In this case, the wall 7 to 11 is formed from a metal material, in particular from the material 1.4301, 1.4310, 1.4510 or 1.4016. In step S1 the device 15 which is made at least partially from a plastic material is also provided. The device 15 may be produced, for example, in the step S1 by means of a plastic injection-molding method.

(25) In a step S2 the device 15 is arranged on the wall 7 to 11, in order to form the liquid chamber 20. The liquid chamber 20 in this case is delimited by the corresponding wall 7 to 11 and the device 15, in particular the storage portion 16 of the device 15. In a step S3 the device 15 is laser-welded to the corresponding wall 7 to 11. For the welding process, preferably a diode laser is used, wherein a feed rate of the laser significantly predetermines the output power of the laser used. The device 15 is positioned by means of a clamping device relative to the corresponding wall 7 to 11 and pressed thereagainst.

(26) The laser welding of the device 15 to the wall 7 to 11 may be carried out, for example, by means of a laser transmission welding method. In this case, the fastening flange 18 has a high transmittance of laser radiation in the laser wavelength range used. The laser radiation is then absorbed by the outer face 22, whereby the fastening flange 18 is at least partially melted thereon. Alternatively, the laser welding may also be carried out by means of a heat conduction joining. As a result, the corresponding wall 7 to 11, for example, may be heated from the inner face 23. The outer face 22 is then heated by heat conduction such that the fastening flange 18 is at least partially melted thereon. Before or during the arrangement of the device 15 on the corresponding wall 7 to 11 in the step S2, the corresponding wall 7 to 11 is at least partially subjected to surface structuring, as already described above. To this end, nano-pulsed laser beams are preferably used.

(27) As a plastic wall is not provided between the liquid chamber 20 and the washing chamber 4, firstly the heat transfer from the liquid chamber 20 to the washing chamber 4 is significantly improved and secondly a material saving is achieved by the elimination of the plastic material. An expensive energy-intensive mirror welding process is dispensed with.

(28) The storage portion 16 of the device 15 may be made in just one variant, the device 15 then being differentiated by the functional portion 17. The greatest advantage of the device 15 being welded directly onto the washing container 2 is in the significantly improved energy diffusion ratio and thus in the markedly improved energy balance. By eliminating the mirror welding, more cost-effective plastic materials with an improved flow index may be used. The injection-molding rate during injection-molding and thus the production capacity may be increased, whereby investment costs may be reduced. By the elimination of the mirror welding process and the use of linear laser welding in the film composite, plastic materials which have improved flow properties may be used. Higher injection-molding rates are also possible in this case. The elimination of the film also improves the diffusion ratios and thus the energy balance. In summary, a clear advantage is produced relative to material and process costs if the laser welding process is used.

(29) Whilst the present invention has been described with reference to exemplary embodiments, the invention may be modified in many different ways.