Method for producing a component for a water bearing appliance and component obtained with such method
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Solution Overview
Problem
Components made from recycled plastic in water-bearing appliances, such as washing machines, often compromise on aesthetics and mechanical properties compared to those made from non-recycled plastic, while efforts to use recycled materials aim to reduce environmental impact and production costs.
Innovation Solution
A method involving co-injection molding, where a non-recycled polymeric material is first injected into a mold to form an external solidified layer, followed by injecting a recycled polymeric material to fill the core, allowing for a cost-effective and aesthetically improved component with reduced 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 deteriorate
Solution Approach 1:
The patent applies local quality by using different material qualities in different regions of the same component. The outer layer uses non-recycled plastic with superior aesthetic appearance and mechanical properties, while the inner core uses recycled plastic for cost-effectiveness and environmental benefits. This allows each region of the component to have the appropriate material quality for its specific function and visibility requirements.
Solution Approach 2:
The patent employs composite materials by combining recycled and non-recycled plastic materials in a layered structure. The component consists of an outer layer made from non-recycled plastic and an inner core made from recycled plastic, creating a composite structure that leverages the advantages of both material types while mitigating their individual disadvantages.
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 deteriorates
Solution Approach 1:
The patent applies local quality by using different material qualities in different regions of the same component. The outer layer uses non-recycled plastic with superior aesthetic appearance and mechanical properties, while the inner core uses recycled plastic for cost-effectiveness and environmental benefits. This allows each region of the component to have the appropriate material quality for its specific function and visibility requirements.
Solution Approach 2:
The patent employs composite materials by combining recycled and non-recycled plastic materials in a layered structure. The component consists of an outer layer made from non-recycled plastic and an inner core made from recycled plastic, creating a composite structure that leverages the advantages of both material types while mitigating their individual disadvantages.
3Strength
If non-recycled plastic material is used for the entire component, then aesthetic appearance and mechanical properties are improved, but production cost increases and environmental impact increases
Solution Approach 1:
The patent applies local quality by using different material qualities in different regions of the same component. The outer layer uses non-recycled plastic with superior aesthetic appearance and mechanical properties, while the inner core uses recycled plastic for cost-effectiveness and environmental benefits. This allows each region of the component to have the appropriate material quality for its specific function and visibility requirements.
Solution Approach 2:
The patent employs composite materials by combining recycled and non-recycled plastic materials in a layered structure. The component consists of an outer layer made from non-recycled plastic and an inner core made from recycled plastic, creating a composite structure that leverages the advantages of both material types while mitigating their individual disadvantages.
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 enhances the aesthetic appearance and mechanical properties of components while reducing production costs and environmental impact by utilizing recycled materials effectively in water-bearing appliances.
Implementation Method 1
injecting from at least one injection point a first not recycled polymeric material into a cavity of a mould for a first time so that said first not recycled polymeric material reaches internal surfaces of said mould and at least partially solidifies to form an external solidified layer
Implementation Method 2
injecting from said at least one injection point, after said first time, a second recycled polymeric material into said mould for a second time so that said second recycled polymeric material fills the core of said cavity and pushes the first not recycled polymeric material not jet solidified
Data Source
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AI summary
The invention relates a method for producing a component (1; 101, 104; 204; 301: 401; 501) for a water bearing appliance. The method comprises the steps of: injecting from an injection point (60; 160) a first not recycled polymeric material (20) into a cavity (56; 156) of a mould (50; 150) for a first time so that the first not recycled polymeric material (20) reaches internal surfaces of the mould (50; 150) and injecting from the injection point (60; 160), after said first time, a second recycled polymeric material (22) into said mould (50; 150).