Two-Component Dispenser Part Seam Structure for Impact Strength
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Solution Overview
Problem
Dispenser parts made from multiple plastic materials often suffer from distortion and weak seams, particularly at side edges, which can lead to cracking under impact forces, compromising their structural integrity and requiring frequent replacement.
Innovation Solution
A two-component injection moulding process is used to create dispenser parts with a seam extending from one side edge to another, employing raised contact surfaces or projections along the seam to enhance strength, where the first component is moulded with steps or projections that melt during the second injection step, ensuring a homogenous and strong bond between materials.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If two components are injection moulded and joined along a seam, then the dispenser part can have different material properties (transparent/opaque sections), but the seam lacks sufficient strength to withstand impact forces
Solution Approach 1:
The patent applies local quality by creating a seam with non-uniform thickness, where the seam thickness varies along its length. The seam is thicker in regions subjected to higher impact forces (such as corners and edges) and thinner in less critical areas. This localized variation in seam thickness provides enhanced strength where needed while maintaining overall structural integrity and allowing different material properties in different sections of the dispenser part.
2Strength
If the seam is reinforced locally to increase strength, then the seam can withstand more force, but the dispenser part becomes more complex to manufacture
Solution Approach 1:
The patent employs parameter changes by varying the seam thickness as a continuous parameter along the seam length rather than using discrete reinforcements. The seam thickness is adjusted based on the expected impact forces at different locations, creating a gradient structure that optimizes strength while avoiding the complexity of multiple separate reinforcement components. This continuous parameter variation is achieved through controlled injection moulding processes.
3Adaptability or versatility
If the seam extends from one side edge to another side edge, then the dispenser part can be made from two similar or different plastic materials with different functions, but the seam becomes vulnerable to distortion and cracking
Solution Approach 1:
The patent applies local quality by creating a seam with non-uniform thickness, where the seam thickness varies along its length. The seam is thicker in regions subjected to higher impact forces (such as corners and edges) and thinner in less critical areas. This localized variation in seam thickness provides enhanced strength where needed while maintaining overall structural integrity and allowing different material properties in different sections of the dispenser part.
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
The method results in a dispenser part with a seam that matches or exceeds the impact strength of the individual components, preventing cracks along the seam and ensuring the dispenser part fractures away from the seam under impact, thus improving durability and reducing replacement needs.
Implementation Method 1
employing raised contact surfaces or projections along the seam to enhance strength, where the first component is moulded with steps or projections that melt during the second injection step
Data Source
Figure 1a~2
Figure 3~4d
Figure 5~6
AI summary
The invention relates to a dispenser part, comprising a first injection moulded plastic component part (17) with an associated first mating surface; a second injection moulded plastic component part (18) having an associated second mating surface; a seam (21) formed by said first mating surface and said second mating surface during injection moulding for joining said first component part and said second component part to define a dispenser part, and component part comprising a front surface, a first and a second side surface each having an edge (22, 23) facing away from the front surface. The resulting seam extends from the edge (22) associated with the first side surface to the edge (23) associated with the second side surface.