Component for a home appliance
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Solution Overview
Problem
Existing injection molding methods for home appliance components are limited by high manufacturing costs due to the use of expensive metallic materials, difficulty in molding large parts, and injection defects at distant locations, along with prolonged manufacturing times.
Innovation Solution
A component design that incorporates a skin layer and core layer, allowing for the use of different materials for visible and non-visible portions, with separate injection gates for each layer, enabling efficient molding of large parts and reducing manufacturing time.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Shape
If the entire exterior of a part is molded with metallic materials, then the sophistication of the appearance is improved, but the manufacturing cost increases
Solution Approach 1:
The patent applies local quality by using metallic resin only for the skin layer that forms the visible outer surface, while the core layer uses recycled resin for non-visible portions. This allows the sophisticated metallic appearance to be localized only where needed for aesthetic purposes, rather than applying expensive metallic materials throughout the entire component.
Solution Approach 2:
The patent employs composite materials by combining metallic resin and recycled resin in a dual-layer injection molding process. The metallic resin forms the outer skin layer providing aesthetic appearance, while the recycled resin forms the inner core layer providing structural support, creating a composite structure that balances appearance sophistication with cost efficiency.
2Device complexity
If a single valve injection molding method is used for skin layer and core layer, then the device complexity is reduced, but the position of the gate is limited and injection defects occur in distant portions
Solution Approach 1:
The patent applies segmentation by dividing the injection molding process into two separate operations: first injecting the core layer through a first valve, then injecting the skin layer through a second valve. This segmentation allows each material to be injected through optimally positioned gates, ensuring proper filling and avoiding injection defects in distant portions of large components.
Solution Approach 2:
The patent transitions from a single-valve single-layer injection approach to a multi-valve multi-layer injection approach, adding the dimension of sequential layer injection. This allows independent control of injection parameters and gate positions for each layer, improving manufacturing precision for large parts.
3Manufacturing precision
If the injection process proceeds slowly to prevent defects, then the manufacturing precision is improved, but the productivity decreases
Solution Approach 1:
The patent applies preliminary action by first injecting the core layer completely before injecting the skin layer. This sequential approach allows the core layer to be properly formed first, providing a stable base that enables faster injection of the skin layer without causing defects, thereby improving overall productivity.
Solution Approach 2:
The patent maintains continuity of useful action by implementing a seamless two-stage injection process where the core layer injection is immediately followed by skin layer injection without interruption. This continuous process eliminates idle time while ensuring proper filling and preventing defects through controlled sequential injection.
Data Source
AI summary
A component for a home appliance of the present disclosure is formed so that at least a portion of the component has both a skin layer made of a first material and a core layer made of a second material, and at least a portion of the component has only a core layer made of a third material, thereby reducing manufacturing costs.