Component for home appliance

Abstract

The present invention relates to a component for a home appliance, and more specifically to a novel component for a home appliance, which comprises a skin layer and a core layer which are formed from mutually different materials, and has excellent light transmittance and durability. According to the present invention, a novel component for a home appliance may be provided, the component, through the injection of dissimilar materials, enabling the reduction of component costs, having excellent light transmittance, and inducing a chemical covalent bond between the dissimilar materials, thereby having excellent durability.

Description

parts for home appliances

[0001] The present invention relates to a component for home appliances, and more specifically, to a novel component for home appliances comprising a skin layer and a core layer formed of different materials, having excellent light transmittance and durability.

[0002] Generally, home appliances are electrical devices provided to the home that utilize energy such as electricity or heat.

[0003] These home appliances include various products such as washing machines, refrigerators, and air purifiers.

[0004] The above-mentioned home appliance may be equipped with a transparent component that allows the interior to be seen with the naked eye.

[0005] These parts are typically formed of glass.

[0006] However, glass components for home appliances have the disadvantage of a high risk of breakage and heavy weight.

[0007] Several materials are known to replace these glass parts.

[0008] However, parts made of materials that can replace glass have the disadvantage of low economic feasibility due to relatively high costs.

[0009] Accordingly, there is a demand for new home appliance components that are economical, can replace glass, and are highly durable.

[0010] The objective of the present invention is to provide a novel component for home appliances that can reduce material costs during molding for the exterior and can replace glass.

[0011] In addition, the objective of the present invention is to provide a novel component for home appliances that can reduce material costs during molding for the exterior and has excellent transparency.

[0012] In addition, the objective of the present invention is to provide a novel component for home appliances that can reduce material costs during molding for the exterior and has excellent durability.

[0013] In addition, the objective of the present invention is to provide a novel component for home appliances that can reduce material costs during molding for the exterior and has excellent transparency and durability.

[0014] The objects of the present invention are not limited to those mentioned above, and other unmentioned objects and advantages of the present invention may be understood from the following description and will be more clearly understood by the embodiments of the present invention. Furthermore, it will be readily apparent that the objects and advantages of the present invention can be realized by the means and combinations thereof set forth in the claims.

[0015] The component for a home appliance according to the present invention, for solving the aforementioned technical problem, has a structure formed by injection molding of a heterogeneous material to reduce material costs and has excellent light transmittance so as to replace glass.

[0016] Specifically, the component for a home appliance according to the present invention comprises a skin layer formed by injection molding with a first material and a core layer formed by injection molding with a second material while located within the skin layer, and the light transmittance of light vertically transmitted through the skin layer and the core layer is 80% or more.

[0017] Here, the difference between the refractive index of the skin layer and the refractive index of the core layer may be less than 0.01.

[0018] Preferably, a chemical covalent bond may be formed at the interface between the skin layer and the core layer. In this case, the chemical covalent bond may include a chemical covalent bond between an epoxy group and a hydroxyl group.

[0019] Preferably, the first material may include SAN (styrene acrylonitrile), and the second material may include PET (polyethylene terephthalate).

[0020] In addition, a component for a home appliance according to another embodiment of the present invention has a structure formed by injection molding of heterogeneous materials to reduce material costs, and its durability is greatly increased by using a compatibilizer having a specific functional group.

[0021] Specifically, a component for a home appliance according to another embodiment of the present invention comprises a skin layer formed by injection molding with a first material and a core layer formed by injection molding with a second material while positioned within the skin layer, wherein the first material comprises a compatibilizer that induces a chemical covalent bond at the interface between the skin layer and the core layer.

[0022] Here, the above compatibilizer may include a monomer having an epoxy group.

[0023] It is preferable that the above-mentioned commercial agent includes a SAN graft GMA (styrene acrylonitrile graft glycidyl methacrylate) copolymer.

[0024] In addition, the first material may include SAN (styrene acrylonitrile), and the second material may include PET (polyethylene terephthalate).

[0025] Preferably, the light transmittance of light vertically transmitted through the skin layer and the core layer may be 80% or more, and the difference between the refractive index of the skin layer and the refractive index of the core layer may be less than 0.01.

[0026] According to the present invention, a new component for home appliances can be provided that can replace glass by reducing component costs through injection molding of heterogeneous materials and having excellent light transmittance.

[0027] In addition, the present invention can reduce part costs through the injection of heterogeneous materials and can provide a novel component for home appliances with excellent transparency by controlling the refractive index between heterogeneous materials.

[0028] In addition, the present invention can reduce part costs through the injection of heterogeneous materials and can provide a novel component for home appliances with excellent durability by inducing chemical covalent bonding between heterogeneous materials.

[0029] In addition to the effects described above, the specific effects of the present invention are described together with the specific details for implementing the invention below.

[0030] FIG. 1 is a front view illustrating a washing machine to which the components for home appliances of the present invention are applied.

[0031] FIG. 2 is a perspective view illustrating a component for a home appliance according to the present invention applied to a washing machine.

[0032] FIG. 3 is a cross-sectional view illustrating a cross-section of a component for a home appliance according to the present invention.

[0033] FIG. 4 is an enlarged view of a portion of the cross-section of a component for a home appliance according to the present invention.

[0034] FIG. 5 is a front view illustrating a refrigerator to which the components for home appliances of the present invention are applied.

[0035] FIG. 6 is a perspective view illustrating a component for a home appliance according to the present invention applied to a refrigerator.

[0036] FIGS. 7 to 10 are perspective views illustrating the components for home appliances of the present invention applied to a refrigerator.

[0037] FIG. 11 is a front view illustrating a washing machine to which the components for home appliances of the present invention are applied.

[0038] FIG. 12 is a perspective view illustrating a component for a home appliance according to the present invention applied to a washing machine.

[0039]

[0040] The aforementioned objectives, features, and advantages are described in detail below with reference to the attached drawings, thereby enabling those skilled in the art to easily implement the technical concept of the present invention. In describing the present invention, detailed descriptions of known technologies related to the present invention are omitted if it is determined that such descriptions would unnecessarily obscure the essence of the invention. Hereinafter, preferred embodiments according to the present invention will be described in detail with reference to the attached drawings. In the drawings, the same reference numerals are used to indicate the same or similar components.

[0041] Singular expressions used in this specification include plural expressions unless the context clearly indicates otherwise. In this application, terms such as "composed of" or "comprising" should not be interpreted as necessarily including all of the various components or steps described in the specification, and should be interpreted as meaning that some of the components or steps may be omitted or additional components or steps may be included.

[0042] Hereinafter, a component for a home appliance according to the present invention will be described in detail with reference to the drawings.

[0043]

[0044] FIG. 1 is a front view illustrating a washing machine (100) to which the component (10) for a home appliance according to the present invention is applied. Referring to FIG. 1, the component (10) for a home appliance according to the present invention may be required to be transparent so that the interior of the home appliance can be visually inspected.

[0045] FIG. 2 is a perspective view illustrating a component (10) for a home appliance according to the present invention, FIG. 3 is a cross-sectional view illustrating a cross-section of a component (10) for a home appliance according to the present invention, and FIG. 4 is an enlarged view illustrating a portion of the cross-section of a component (10) for a home appliance according to the present invention.

[0046] First, a component (10) for a home appliance according to an embodiment of the present invention will be described with reference to FIGS. 2 to 4. The component (10) for a home appliance according to the present invention is formed in various shapes and includes a skin layer (1) formed by injection molding with a first material and a core layer (2) formed by injection molding with a second material while located within the skin layer (1), and has a light transmittance of light that is vertically transmitted through the skin layer (1) and the core layer (2) of 80% or more.

[0047] Here, the light transmittance refers to the transmittance of light transmitted perpendicularly to the surface of the component, and the light transmittance can be measured using a spectrophotometer or FTIR spectroscopy.

[0048]

[0049] At this time, preferably, the difference between the refractive index of the skin layer (1) and the refractive index of the core layer (2) may be less than 0.01. If the difference between the refractive index of the skin layer (1) and the refractive index of the core layer (2) is 0.01 or more, the haze value may increase and transparency may be lost.

[0050]

[0051] A component (10) for a home appliance according to one embodiment of the present invention comprises a skin layer (1) and a core layer (2) formed by injection molding different materials. Referring to FIG. 4, the skin layer (1) corresponds to a surface portion exposed to the outside of the component, and the core layer (2) is located inside the skin layer (1). Accordingly, it is preferable that the skin layer (1) be formed of a high-hardness functional material, and the core layer (2) be formed of a high-strength material. However, since the core layer (2) is not an externally exposed portion, there is no need to use high-cost functional materials.

[0052]

[0053] As previously mentioned, the skin layer (1) and the core layer (2) are formed from different materials. Accordingly, if the part (10) receives a large impact, the skin layer (1) and the core layer (2) may separate from each other at the interface. In other words, while a part formed by injection molding of different materials can reduce the use of expensive materials and thus reduce material costs, as a trade-off, there is a problem in that if the part receives an impact, the skin layer (1) and the core layer (2), which are formed from different materials, may separate from each other at the interface.

[0054] In one embodiment of the present invention, a component (10) for a home appliance may have a chemical covalent bond formed at the interface between the skin layer (1) and the core layer (2). Due to the chemical covalent bond, the skin layer (1) and the core layer (2) of the component (10) for a home appliance of the present invention are not easily separated even when subjected to impact.

[0055]

[0056] The above chemical covalent bond may include a chemical covalent bond between an epoxy group and a hydroxyl group. Preferably, the epoxy group may be contained in the resin included in the first material, and the hydroxyl group may be contained in the resin included in the second material. Accordingly, when the first material and the second material are injected to form a skin layer (1) and a core layer (2), respectively, the epoxy group and the hydroxyl group may form a strong chemical covalent bond at the interface between the skin layer (1) and the core layer (2).

[0057] Additionally, the first material may further include a compatibilizer comprising a monomer having an epoxy group. The epoxy group of the monomer included in the compatibilizer may form a strong chemical covalent bond with the hydroxyl group contained in the second material.

[0058] Any known compatibilizer having an epoxy group can be used as the above compatibilizer, but it is preferable to include a SAN graft GMA (styrene acrylonitrile graft glycidyl methacrylate) copolymer in relation to the main resin belonging to the first material and the second material.

[0059]

[0060] As a specific example of the first material forming the skin layer (1), the first material may include resins such as SAN (styrene acrylonitrile), SMMA (styrene-methyl methacrylate), MS (methyl methacrylate-styrene), PC (polycarbonate), mABS (modified acrylonitrile-butadirene-styrene), PCTG (polycyclohexylene dimethylene terephthalate-co-glycol), GPPS (general-purpose polystyrene), and PMMA (polymethyl methacrylate).

[0061] In addition, as a specific example of the second material forming the core layer (2), the second material may include resins such as PET (polyethylene terephthalate), PCTA (polycyclohexylene dimethylene terephthalate-co-adipate), PCTG (polycyclohexylene dimethylene terephthalate-co-glycol), PC (polycarbonate), and PMMA (polymethyl methacrylate).

[0062]

[0063] Here, considering the strength, cost, and relationship between the skin layer and the core layer of the component, the first material may include SAN (styrene acrylonitrile) as the main resin, and the second material may include PET (polyethylene terephthalate) as the main resin.

[0064]

[0065] Next, a component (10) for a home appliance according to another embodiment of the present invention will be described with reference to FIGS. 2 to 4.

[0066] The component (10) for a home appliance according to the present invention includes a skin layer (1) and a core layer (2) formed by injection molding different materials. Accordingly, when the component (10) is subjected to impact, the skin layer (1) and the core layer (2) may separate from each other at the interface. In other words, a component formed by injection molding of different materials can reduce the use of expensive materials, thereby reducing material costs; however, as a trade-off, there is a problem in that when the component is subjected to impact, the skin layer (1) and the core layer (2), formed from different materials, may separate from each other at the interface.

[0067] In another embodiment of the present invention, a component (10) for a home appliance has a chemical covalent bond formed at the interface between the skin layer (1) and the core layer (2), and due to the chemical covalent bond, the skin layer (1) and the core layer (2) are not easily separated at the interface even when impact is applied.

[0068] More specifically, a component (10) for a home appliance according to another embodiment of the present invention is formed in various shapes and includes a skin layer (1) formed by injection molding with a first material and a core layer (2) formed by injection molding with a second material while located within the skin layer (1), and the first material includes a compatibilizer that induces a chemical covalent bond at the interface (S) between the skin layer (1) and the core layer (2).

[0069]

[0070] The above compatibilizer includes a monomer having an epoxy group and induces a chemical covalent bond at the interface (S) between the skin layer (1) and the core layer (2).

[0071] More specifically, the epoxy group contained in the above-mentioned compatibilizer forms a strong chemical covalent bond with the functional group contained in the core layer (2) at the interface (S) between the skin layer (1) and the core layer (2). Due to the above-mentioned chemical covalent bond, the skin layer (1) and the core layer (2) of the home appliance component (10) of the present invention are not easily separated even when subjected to impact.

[0072] As an example, the chemical covalent bond may include a chemical covalent bond between an epoxy group and a hydroxyl group. Preferably, the hydroxyl group may be contained in the resin included in the second material. Accordingly, when the first material and the second material are injected to form a skin layer (1) and a core layer (2), respectively, the epoxy group and the hydroxyl group may form a strong chemical covalent bond at the interface (S) between the skin layer (1) and the core layer (2).

[0073] The above compatibilizer may be an oligomer, polymer, or copolymer containing a monomer having an epoxy group.

[0074] Any known compatibilizer having an epoxy group can be used as the above compatibilizer, but it is preferable to include a SAN graft GMA (styrene acrylonitrile graft glycidyl methacrylate) copolymer in relation to the main resin belonging to the first material and the second material.

[0075]

[0076] As a specific example of the first material forming the skin layer (1), the first material may include resins such as SAN (styrene acrylonitrile), SMMA (styrene-methyl methacrylate), MS (methyl methacrylate-styrene), PC (polycarbonate), mABS (modified acrylonitrile-butadirene-styrene), PCTG (polycyclohexylene dimethylene terephthalate-co-glycol), GPPS (general-purpose polystyrene), and PMMA (polymethyl methacrylate).

[0077] In addition, as a specific example of the second material forming the core layer (2), the second material may include resins such as PET (polyethylene terephthalate), PCTA (polycyclohexylene dimethylene terephthalate-co-adipate), PCTG (polycyclohexylene dimethylene terephthalate-co-glycol), PC (polycarbonate), and PMMA (polymethyl methacrylate).

[0078]

[0079] Here, considering the strength, cost, and relationship between the skin layer and the core layer of the component, the first material may include SAN (styrene acrylonitrile) as the main resin, and the second material may include PET (polyethylene terephthalate) as the main resin.

[0080] Particularly preferably, the first material may include SAN (styrene acrylonitrile) as the main resin and SAN graft GMA (styrene acrylonitrile graft glycidyl methacrylate) copolymer as the compatibilizer, and the second material may include PET (polyethylene terephthalate) as the main resin.

[0081]

[0082] In addition, the component (10) for a home appliance according to the present invention may be given transparency so that the interior of the home appliance can be visually inspected.

[0083] Accordingly, the light transmittance of light vertically passing through the skin layer (1) and the core layer (2) may be 80% or more.

[0084] Here, the light transmittance refers to the transmittance of light transmitted perpendicularly to the surface of the component, and the light transmittance can be measured using a spectrophotometer or FTIR spectroscopy.

[0085] At this time, preferably, the difference between the refractive index of the skin layer (1) and the refractive index of the core layer (2) may be less than 0.01. If the difference between the refractive index of the skin layer (1) and the refractive index of the core layer (2) is 0.01 or more, the haze value may increase and transparency may be lost.

[0086]

[0087] In addition, Figures 5 to 12 illustrate various home appliances and components that can be applied thereto.

[0088] FIG. 5 is a front view illustrating a refrigerator (200) to which the appliance component (20) of the present invention is applied. Referring to FIG. 6 to FIG. 10, various embodiments of appliance components (21, 22, 23, 24, 25) that can be applied to a refrigerator are illustrated.

[0089] Additionally, FIG. 11 is a front view illustrating a washing machine (300) to which the component (30) for a home appliance of the present invention is applied. Referring to FIG. 12, an embodiment of the component (30) for a home appliance that can be applied to the washing machine (300) is illustrated.

[0090] As such, the component for a home appliance according to the present invention can be implemented in various forms illustrated in the drawings above.

[0091]

[0092] <Example>

[0093]

[0094] 1. Manufacturing of components for home appliances

[0095] A component for a home appliance was manufactured according to the following manufacturing example using a double injection molding method.

[0096] A first material forming a skin layer was injected into the mold, and a second material different from the first material and forming a core layer was injected. Subsequently, the injection of the second material was stopped, and then the injection of the first material was stopped. The injection and cessation of each material were all controlled by a dual injection molding machine.

[0097] The first material forming the skin layer consists of a resin composition containing the components listed in Table 1 below. The second material forming the core layer also consists of a resin composition containing the components listed in Table 1 below. The content ratio of the first material to the second material in each manufacturing example is 6:4. For example, if 60g of the first material is used, 40g of the second material is used. In addition, in Manufacturing Example 1, 0.5% by weight of the compatibilizer was used based on 100% by weight of the first material.

[0098]

[0099] Manufacturing Example 1 Material (Skin Layer) 2 Material (Core Layer) Main Resin Compatibility Agent Main Resin 1 SANSAN graft GMAPET 2 SAN-PET 3 PC-PET 4 PMMA-PET 5 mABS-PET

[0100] 2. Analysis of Light Transmittance and Haze

[0101] The light transmittance and haze for each preparation example were measured and analyzed. Both light transmittance and haze were measured using a spectrophotometer.

[0102]

[0103] Manufacturing Tracer Transmittance (%) Haze (%) Refractive Index of Skin Layer Refractive Index of Core Layer 189.8 2.15 1.5 71.5 7289.8 2.15 1.5 71.5 735 1100 1.5 91.5 746 5.16 5.11 471.5 758 2.5 93.3 1.5 41.5 7

[0104] Referring to Table 2, the light transmittance of Manufacturing Examples 1, 2, and 3 all corresponds to 80% or more, making them applicable to transparent parts.

[0105] However, since the parts according to the manufacturing example were manufactured by injection molding heterogeneous materials, the haze value increased depending on the refractive indices of the skin layer and the core layer.

[0106] For example, Manufacturing Example 5 has excellent light transmittance, but the haze value is measured to be high because the difference in refractive index between the skin layer and the core layer is large.

[0107] Accordingly, Manufacturing Examples 1 and 2, in which the skin layer uses SAN material and the core layer uses PET material, can be preferably used for parts requiring transparency.

[0108]

[0109] 3. Durability Evaluation

[0110] The durability of the parts was evaluated for Manufacturing Examples 1 and 2.

[0111] Specifically, the durability of Preparation Examples 1 and 2 was evaluated by applying the same physical impact to the surfaces of Preparation Examples 1 and 2.

[0112] The intensity of the physical impact was controlled to the extent that the skin layer and the core layer of Manufacturing Example 2 could be separated from each other at the interface and broken, and the evaluation was conducted.

[0113]

[0114] Although the same impact was applied to both Manufacturing Example 1 and 2, in Manufacturing Example 2, a separation phenomenon was observed at the interface between the skin layer and the core layer, whereas in Manufacturing Example 1, no separation phenomenon was observed at the interface between the skin layer and the core layer and it was not damaged.

[0115] In the case of Preparation Example 1, the epoxy groups of the compatibilizer and the hydroxyl groups contained in the PET of the core layer form a strong covalent bond at the interface between the skin layer and the core layer. Accordingly, Preparation Example 1 was not damaged even by an impact strong enough to cause Preparation Example 2 to be damaged.

[0116]

[0117] 4. Content analysis of the skin layer and core layer

[0118] Preparation Examples 1-1 to 1-3 were prepared by changing the amounts of the first material and the second material as shown in Table 3 below. Preparation Examples 1-1 to 1-3 used the same materials as Preparation Example 1, but only the content was changed.

[0119]

[0120] Content ratio of Manufacturing Example 1 material and 2 material 16:41-18:21-27:31-35:5

[0121] It was confirmed that the dimensions of the parts manufactured through Manufacturing Examples 1, 1-1, and 1-2 all fell within the tolerance range. However, it was confirmed that in Manufacturing Example 1-3, a change in dimensions occurred as the core layer protruded to the outside of the skin layer.

[0122] It can be confirmed that Manufacturing Example 1, in which the content ratio of the first material to the second material is 6:4, is the most desirable in terms of the appearance, strength, and manufacturing cost of the part.

[0123]

[0124] Although the present invention has been described above with reference to the illustrated drawings, the present invention is not limited by the embodiments and drawings disclosed in this specification, and it is obvious that various modifications can be made by a person skilled in the art within the scope of the technical concept of the present invention. Furthermore, even if the effects of the configuration of the present invention were not explicitly described while explaining the embodiments of the present invention above, it is natural to acknowledge that the effects predictable by said configuration should also be recognized.

Claims

1. In a component for a home appliance formed in various shapes, It includes a skin layer formed by injection molding with a first material, and a core layer formed by injection molding with a second material while located within the skin layer. The light transmittance of light vertically transmitted through the skin layer and the core layer is 80% or more Parts for home appliances.

2. In Paragraph 1, The difference between the refractive index of the skin layer and the refractive index of the core layer is less than 0.01 Parts for home appliances.

3. In Paragraph 1, Chemical covalent bonds are formed at the interface between the skin layer and the core layer. Parts for home appliances.

4. In Paragraph 3, The above chemical covalent bond is Includes chemical covalent bonds between epoxy groups and hydroxyl groups Parts for home appliances.

5. In Paragraph 1, The above first material includes SAN (styrene acrylonitrile), and The above second material includes PET (polyethylene terephthalate). Parts for home appliances.

6. In Paragraph 5, The above-mentioned first material further comprises a compatibilizer including a monomer having an epoxy group. Parts for home appliances.

7. In Paragraph 6, The above-mentioned commercial agent comprises a SAN graft GMA (styrene acrylonitrile graft glycidyl methacrylate) copolymer. Parts for home appliances.

8. In a component for a home appliance formed in various shapes, It includes a skin layer formed by injection molding with a first material, and a core layer formed by injection molding with a second material while located within the skin layer. The first material comprises a compatibilizer that induces a chemical covalent bond at the interface between the skin layer and the core layer. Parts for home appliances.

9. In Paragraph 8, The above commercially available product A monomer having an epoxy group Parts for home appliances.

10. In Paragraph 9, The above commercially available product SAN graft GMA (styrene acrylonitrile graft glycidyl methacrylate) copolymer comprising Parts for home appliances.

11. In Paragraph 8, The above first material includes SAN (styrene acrylonitrile), and The above second material includes PET (polyethylene terephthalate). Parts for home appliances.

12. In Paragraph 8, The light transmittance of light vertically transmitted through the skin layer and the core layer is 80% or more Parts for home appliances.

13. In Paragraph 12, The difference between the refractive index of the skin layer and the refractive index of the core layer is less than 0.01 Parts for home appliances.

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