Co-Injected Appliance Component With Recycled Core and Clean Surface
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Solution Overview
Problem
Components made from recycled plastic in water-bearing appliances, such as laundry and dish washing machines, often compromise on aesthetic appearance and mechanical properties, while also increasing production costs and environmental impact compared to components made from non-recycled plastics.
Innovation Solution
Aesthetic components for water-bearing appliances are created using a combination of a non-recycled polymeric material as the external layer and a recycled polymeric material as the core, with the two materials forming a one-piece monolithic body through a co-injection moulding process, optimizing aesthetics and mechanical properties while reducing material consumption and environmental impact.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If recycled plastic material is used to produce components, then production cost is reduced and environmental impact is reduced, but aesthetic appearance and mechanical properties worsen
Solution Approach 1:
The patent applies composite materials by combining recycled plastic material with non-recycled plastic material in a single component. The recycled material provides cost and environmental benefits, while the non-recycled material compensates for mechanical property deficiencies, creating a composite structure that achieves both economic and performance goals
Solution Approach 2:
The patent implements local quality by using recycled plastic material specifically in non-visible or less critical areas of the component, while applying non-recycled plastic material in visible or high-stress areas. This localized approach optimizes material usage based on functional and aesthetic requirements
2Ease of manufacture
If recycled plastic material is used to produce components, then production cost is reduced and environmental impact is reduced, but aesthetic appearance worsens
Solution Approach 1:
The patent uses composite materials combining recycled and non-recycled plastics, where the non-recycled material is strategically placed in visible areas to maintain aesthetic appearance, while the recycled material is used in hidden areas to reduce cost and environmental impact
Solution Approach 2:
The patent applies local quality by differentiating material selection based on the component's spatial characteristics - using non-recycled material in aesthetically critical zones and recycled material in non-visible zones, thereby optimizing both appearance and cost
3Strength
If non-recycled plastic material is used for the entire component, then aesthetic appearance and mechanical properties are maintained, but production cost increases and environmental impact increases
Solution Approach 1:
The patent applies local quality by selectively using non-recycled plastic material only in areas where mechanical properties and aesthetics are critical, while using recycled material in areas where these properties are less important, thereby optimizing cost while maintaining necessary performance
Solution Approach 2:
The patent uses composite materials to combine the advantages of both recycled and non-recycled plastics, creating a hybrid structure that achieves cost efficiency through recycled material usage while maintaining mechanical integrity through strategic non-recycled material placement
Data Source
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AI summary
The invention relates an aesthetic component (1, 4; 104; 101; 201) for a water bearing appliance. The component (1, 4; 104; 101; 201) comprises a first polymeric material (20) and a second polymeric material (22). The external surface (80) of the component (1, 4; 104; 101; 201) is at least partially constituted by the first polymeric material (20) and the first polymeric material (20) covers the second polymeric material (22). The second polymeric material (22) comprises a recycled polymeric material.