Apparatus and method for the production of a component in plastic material
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Solution Overview
Problem
Existing methods for producing plastic components with transparent areas in household appliances face challenges such as inadequate sealing, high production costs, assembly complexity, and defects that compromise transparency and aesthetic appearance.
Innovation Solution
A method and apparatus for producing a plastic component with a first opaque layer and a second transparent layer, where the transparent area is integrated within the component, using a coupling protuberance to maintain separation during injection, ensuring a hermetic seal and high transparency without joint lines.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Shape
If separate layers are made and coupled together to create transparent areas, then aesthetic appearance is improved, but assembly complexity and seal reliability deteriorate
Solution Approach 1:
The patent merges the transparent window and opaque body into a single integrated component made from a single layer of plastic material. The injection molding process creates both the transparent window area and the opaque body structure simultaneously, eliminating the need for separate assembly steps and ensuring inherent seal reliability without additional sealing measures.
2Shape
If separate layers are coupled together to provide aesthetic appearance, then visual appeal is improved, but seal reliability and leakage prevention deteriorate
Solution Approach 1:
The invention combines the transparent window and opaque body into one monolithic structure. Since both portions are formed from the same continuous layer of plastic material through injection molding, there are no interfaces or joints where leakage could occur, ensuring complete seal reliability while maintaining the desired aesthetic appearance.
3Manufacturing precision
If dedicated molds are used for transparent elements, then manufacturing precision is improved, but production cost and device complexity increase
Solution Approach 1:
The patent employs a universal injection mold that can produce both the transparent window area and the opaque body structure in a single operation. The mold design includes features such as a transparent window portion and an opaque portion that are both formed simultaneously, eliminating the need for dedicated molds for different components and reducing overall device complexity.
4Manufacturing precision
If mechanical working processes are used to create apertures, then transparency quality is improved, but production cost and manufacturing complexity increase
Solution Approach 1:
The invention performs the aperture creation action during the initial injection molding process rather than as a subsequent mechanical working step. The mold cavity is designed with the aperture geometry built-in, so the transparent window area is formed directly during material injection, eliminating the need for costly and complex post-processing mechanical operations.
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
This approach enables efficient, cost-effective production with reduced scrappage, high productivity, and a hermetic seal, while maintaining the transparency and aesthetic appeal of the component.
Implementation Method 1
a first injection unit configured to inject a first plastic material into the first molding volume
Implementation Method 2
At least one of either the first matrix or the punch comprises at least one coupling protuberance configured to maintain separation between the punch and the matrix during the injection
Data Source
Figure 1~3
Figure 4~4c
Figure 5~8
AI summary
Embodiments described here concern a method and an apparatus for the production of a component made of plastic material suitable to be used as the containing body, or casing, of a household appliance, or as a receptacle. The component comprises a first layer and a second layer, which at least partly covers the first layer. Method for the production of a component (10) made of plastic material, suitable to form a containing body, or casing, of a household appliance (50), or of a receptacle, and provided with at least one transparent area (T), characterized in that said method comprises: - a first step of injecting a first opaque plastic material into a first molding volume (VI) defined between a punch (29) and a first matrix (30) provided with a first molding surface (33) for the production of a first internal layer (11), wherein during said first step the method provides to limit at least one portion of the first molding volume (VI) in order to produce an exposed area (S) in said first layer (11); - a second step of injecting a second at least partly transparent plastic material into a second molding volume (V2) defined between said first layer (11) obtained in the first injection step, said punch (29), and a second matrix (34) for the production of a second layer (12), wherein during said second injection step said method provides to cover said exposed area (S) with said second material so as to obtain a transparent area (T) in said component (10).