EVA-Laminated Mirror Furniture Doors for Sealed Light Zones
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Solution Overview
Problem
Mirror furniture doors with opaque or transparent zones face issues with dust, dirt, and water penetration at the edges, compromising their sealing and functionality when used as mirrors.
Innovation Solution
The solution involves bonding two mirrors with their back surfaces coated in metal and varnish, using an EVA film to separate and bond them, and applying additional EVA film in the light-permeable zones to ensure proper sealing and facilitate lamination under vacuum, which removes air bubbles and simplifies the installation process.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Illumination intensity
If two mirrors are bonded together with EVA film to create light-permeable zones, then light transmission and aesthetic functionality are improved, but dust, dirt, and water penetration at the edges occur
Solution Approach 1:
The patent divides the mirror door into distinct functional zones: sealed opaque zones and light-permeable transparent zones. By segmenting the bonding structure and applying different sealing measures to different zones, the solution allows light transmission where needed while preventing harmful factor penetration at edges through proper sealing segmentation.
Solution Approach 2:
The patent introduces an intermediary sealing layer or sealing mechanism at the edges of the bonded mirrors. This intermediary element mediates between the need for light transmission through the EVA film and the requirement to prevent dust, dirt, and water penetration, solving the contradiction by providing a dedicated sealing interface.
2Reliability
If additional EVA film is applied in light-permeable zones to ensure sealing, then edge sealing is improved, but manufacturing complexity increases
Solution Approach 1:
The patent applies additional EVA film in light-permeable zones as a preliminary sealing measure before final assembly. This preliminary action ensures that edge sealing is already in place before the mirrors are bonded together, simplifying the overall manufacturing process by pre-preparing sealing elements rather than attempting to seal edges after assembly.
Solution Approach 2:
The patent modifies the thickness or properties of the EVA film in specific zones to achieve proper sealing. By changing parameters such as film thickness, bonding temperature, or pressure in light-permeable zones, the solution achieves reliable edge sealing without requiring fundamentally different manufacturing processes.
3Reliability
If mirrors are bonded with metal and varnish coating, then protective function and aesthetics are improved, but light transmission in designated zones is blocked
Solution Approach 1:
The patent applies different surface treatments to different zones of the mirrors. Metal and varnish coatings are applied to opaque zones for protection and aesthetics, while light-permeable zones are left with different properties (such as sandblasted or coated with transparent materials) to allow light transmission. This local differentiation of surface quality resolves the contradiction between protective function and light transmission.
Solution Approach 2:
The patent uses composite material structures where different layers serve different functions. The mirror assembly comprises multiple layers including reflective coatings, protective varnish, and transparent bonding films (EVA), where each material contributes specific properties. The composite structure allows simultaneous achievement of protection, reflection, and light transmission in different zones.
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 method effectively seals the edges of the mirror doors, preventing dust, dirt, and water from entering while allowing light to pass through, enhancing both functionality and aesthetics.
Implementation Method 1
bonding the back surfaces of both mirrors dusted with a layer of metal and covered by protective varnish with a layer of an EVA (ethylene-vinyl acetate) film, wherein the furniture door leaf arranged in this manner is subjected to lamination to bond the two panels together by liquefying at a high temperature the EVA film layer separating the back surfaces of both mirrors
Implementation Method 2
Before the start of lamination of a door leaf arranged in one assembly, the door assembly is placed under vacuum to vent the space between the two mirrors arranged in one assembly
Data Source
Figure 1~2
Figure 3~5
Figure 6~7
AI summary
A mirror furniture door have a layered structure. They comprise two mirrors (1,2) connected together by bonding their back surfaces dusted with a layer of metal and covered by protective varnish (3). The mirrors (1,2) are connected by means of a connecting EVA (ethylene-vinyl acetate) film layer (4). The door on both sides comprises the mirrors (1,2), wherein both said mirrors are bonded together by means of the EVA film layer (4) separating them. Each of the mirrors (1,2) comprises opaque or transparent zones (5), without the protective varnish (3) and dusted metal layer. The opaque or transparent zones (5) in both mirrors (1,2) put together overlap one another, so that in the mirrors (1,2) bonded together light can pass through the opaque or transparent zones (5). At least one opaque or transparent zone (5) of at least one mirror (1,2) comprises an additional EVA film (6) sheet. A method of manufacturing the mirror furniture door involves cutting the two mirrors (1,2) to size, and then sandblasting the zones of the mirrors (1,2) to be opaque or transparent in a sandblasting chamber to remove the protective varnish (3) layers from these places. Between the back surfaces of the mirrors (1,2), the EVA film layer (4) is arranged, and the furniture door leaf arranged in this manner is subjected to lamination to liquefy the EVA film layer (4) and bond the two mirrors (1,2) together. Before the start of lamination, the door assembly is placed under vacuum. In the first stage in the lamination zone the temperature is increased to 60°C-80°C and this temperature is maintained for a period of about 20-40 minutes. Then, in the second lamination stage, the temperature in this lamination zone is increased to 110°C-135°C and this temperature is maintained for 20-40 minutes. When the annealing is finished, the temperature in the annealing zone is decreased to the ambient temperature.