Method and apparatus for the production of a component made of plastic material, and component made of plastic material
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Solution Overview
Problem
Existing methods for producing plastic components with multiple layers face issues such as non-homogeneous cooling, formation of joint lines, air bubbles, and structural defects due to varying thicknesses, especially in three-dimensional surfaces, leading to aesthetic and structural problems.
Innovation Solution
A method and apparatus that involve injecting a first plastic material into a molding volume to form a first layer with channels corresponding to the shape of recessed portions, followed by injecting a second material to create a three-dimensional external layer with alternating protruding and recessed portions, using molding assemblies with specific configurations to ensure uniform thickness and prevent defects.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Shape
If the second layer of material is overmolded on the first layer to create a three-dimensional surface finish with alternating protruding and recessed portions, then an aesthetically pleasing external surface is obtained, but joint lines and structural defects form due to non-homogeneous cooling and uneven material flow
Solution Approach 1:
The patent applies preliminary action by creating channels and cavities in the first layer before injecting the second material. These pre-formed structures guide the material flow and ensure uniform filling of the second layer, preventing joint lines and defects while maintaining the desired three-dimensional surface finish.
Solution Approach 2:
The patent implements local quality by varying the thickness of the first layer in different zones to compensate for the varying thickness of the second layer. The first layer has greater thickness in zones corresponding to recessed portions and lesser thickness in zones corresponding to protruding portions, ensuring uniform cooling and material flow throughout the component.
2Shape
If the second layer is injected to cover the first layer completely, then a uniform aesthetic appearance is achieved, but the underlying layer cannot be visible and design flexibility is reduced
Solution Approach 1:
The patent applies local quality by selectively varying the coverage of the second layer across different zones. In some zones, the second layer completely covers the first layer for uniform appearance, while in other zones, the second layer is thinner or absent to reveal the underlying layer, creating visible patterns and enhancing design flexibility.
3Strength
If the first layer is made with greater thickness to act as a structural component, then structural strength is improved, but the second layer cannot provide sufficient aesthetic surface finish
Solution Approach 1:
The patent employs composite materials by combining two layers with different functions. The first layer provides structural strength with optimized thickness distribution, while the second layer provides aesthetic surface finish. The channels and cavities in the first layer enable the second layer to achieve uniform thickness and desirable surface characteristics despite the varying thickness of the structural first layer.
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 solution achieves a uniformly filled second layer with a pleasing three-dimensional aesthetic effect, preventing joint lines and structural defects while ensuring hermetic seals and high productivity.
Implementation Method 1
a first injection device (31) configured to inject a first plastic material into a first molding volume (V1) to make a first layer (11)
Implementation Method 2
the non-homogeneous cooling, in the different portions which have a different thickness to each other. This non-homogeneous cooling of the second layer of material can cause the formation of structural and aesthetic defects
Data Source
Figure 1~3
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Figure 5~8
AI summary
Embodiments described here concern a method and an apparatus for the production of a component made of plastic material suitable to be used as the containing body, or casing, of a household appliance, or as a receptacle. The component comprises a first layer and a second layer, which at least partly covers the first layer. Method for the production of a component (10) made of plastic material, suitable to form a containing body, or casing of a household appliance (50), or of a receptacle, comprising: - a first step of injecting a first plastic material into a first molding volume (VI) defined between a punch (29) and a first matrix (30) to make a first layer (11); - a second step of injecting a second plastic material into a second molding volume (V2) defined between said first layer (11) obtained in the first injection step and a second matrix (34), to make a second layer (12), characterized in that it provides to make said second layer (12) having an external surface provided with a three-dimensional finish, comprising an alternation of protruding portions (17) and recessed portions (18) and in that, during the first injection step, it provides to make, on said first layer (11), channels, or filling cavities (19), correlated to the shape and position of said recessed portions (18) of said second layer (12), suitable to compensate for the difference in thickness between said protruding portions (17) and said recessed portions (18), so as to obtain, in said second injection step, a substantially uniform filling flow of said second material.