Double-Injected Home Appliance Component for Crack-Free Core-Skin Bonding
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Solution Overview
Problem
Double injection molding of home appliance components often results in deformation, shrinkage, and cracks due to temperature differences and pressure, leading to defects at the interface between the core and skin materials.
Innovation Solution
A method of double-injection molding using one mold with two nozzles to simultaneously inject a metallic skin layer and a recycled resin core layer, with controlled thickness variations based on shape, to minimize exposure of the core and enhance adhesion.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If insert injection molding is used to manufacture home appliance components with core and skin materials, then functional properties and appearance are improved, but deformation, shrinkage, and cracks occur due to temperature differences and pressure
Solution Approach 1:
The patent combines the core material injection and skin material injection into a single integrated process using one mold with two nozzles. This simultaneous double injection molding eliminates the need to transfer the core between molds, maintaining temperature stability and preventing deformation and shrinkage that occur in sequential insert injection molding
Solution Approach 2:
The patent introduces a temperature control mechanism as an intermediary between the injection process and the mold. Temperature control plates are positioned between the nozzles and the mold cavity to maintain optimal temperature during simultaneous injection, preventing thermal shock and subsequent deformation while enabling the use of temperature-sensitive recycled materials
2Reliability
If insert injection molding is used with high-temperature skin material, then metallic appearance and antibacterial functions are achieved, but cracks occur in the core due to pressure and temperature difference
Solution Approach 1:
The patent combines core injection and skin injection into a single simultaneous process, allowing the core material to set at optimal temperature before skin material is applied. This eliminates the pressure-induced cracking that occurs when pre-formed cores are subjected to high-pressure skin injection
Solution Approach 2:
The patent changes the temperature parameters during the injection process by introducing temperature control plates. The temperature is maintained within a specific range (20-50°C) during simultaneous injection, preventing thermal shock to the core material and avoiding cracks while still allowing the skin material to achieve its metallic appearance and antibacterial properties
3Reliability
If insert injection molding is used to manufacture home appliance components, then functional properties are improved, but adhesion at the interface between core and skin decreases
Solution Approach 1:
The patent combines core injection and skin injection into a single simultaneous process where both materials are injected at the same time into the same mold cavity. This ensures optimal bonding conditions from the beginning, creating strong adhesion at the interface between core and skin materials
Solution Approach 2:
The patent optimizes the temperature and pressure parameters during simultaneous injection to enhance adhesion. By controlling the temperature within 20-50°C and maintaining appropriate pressure levels, the patent ensures proper molecular bonding between core and skin materials at the interface, resulting in strong adhesion while maintaining functional properties
4Adaptability or versatility
If separate injection molding machines and molds are used for core and skin, then manufacturing flexibility is maintained, but manufacturing cost and process complexity increase
Solution Approach 1:
The patent merges two separate injection molding systems (core machine and skin machine with separate molds) into a single integrated system with one mold containing two nozzles. This reduces equipment investment, simplifies the manufacturing process, and eliminates the need to transfer cores between molds while maintaining the ability to manufacture different component types
Solution Approach 2:
The patent designs a universal mold that can accommodate different core and skin material combinations for various home appliance components. The single mold with dual nozzles can be configured to manufacture different types of components (refrigerator panels, washing machine parts, etc.) by changing the injection parameters and material selection, providing manufacturing flexibility without requiring separate dedicated equipment for each component type
Data Source
AI summary
A component for a home appliance made of a plate having various shapes, the component having a cross-section including a skin layer made of a first material by injection-molding; and a core layer disposed on the skin layer and made of a second material, which is different from the first material, by injection-molding. The cross-section may have a curved area and a straight area, and a thickness of the curved area may be greater than a thickness of the straight area.