Hybrid pigmented hot stitched color liner system
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Solution Overview
Problem
Conventional methods for producing pigmented liners for appliances, especially refrigeration appliances, face challenges such as increased complexity, cost, and susceptibility to scratches due to the need for multiple extrusion runs and adhesives, which affect color matching and manufacturing yield, and result in visible wear and discoloration.
Innovation Solution
A method involving the creation of a polymeric capping layer with a high pigment concentration, laminated with a polymeric base layer at the base layer formation temperature without adhesives, to form a liner with a textured pattern that protects against scratches and maintains aesthetic appearance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Quantity of substance
If pigments are added to multiple extruders for multi-layer liners, then color can be incorporated in each layer, but the complexity, repeatability, and manufacturing cost of matching colors increases significantly
Solution Approach 1:
The patent combines multiple pigment addition operations into a single extrusion process. The multi-layer liner is formed in one continuous extrusion operation where pigments are added to the extruder feed, eliminating the need for separate extruders for each layer and significantly reducing process complexity while maintaining color consistency across layers.
Solution Approach 2:
The single extruder system performs multiple functions simultaneously: it extrudes the liner material, incorporates pigments for coloration, and forms multiple layers in one operation. This multi-functional approach replaces the need for multiple specialized extruders, reducing manufacturing complexity while achieving the same color incorporation goal.
2Quantity of substance
If significant loadings of pigments are employed in multi-layer liners, then desired color can be achieved, but down-stream processes such as thermal forming can lead to local discoloration and yield losses
Solution Approach 1:
The patent optimizes pigment concentration parameters to achieve the desired color intensity while remaining below thresholds that cause discoloration during thermal processing. By carefully controlling the amount of pigment added to the extruder feed, the formulation achieves target coloration without compromising color stability during downstream thermal forming operations.
3Manufacturing precision
If multiple and cost-intensive extrusion runs are required to fabricate a liner having multiple extruded layers with pigments, then color matching can be achieved, but manufacturing time and cost increase
Solution Approach 1:
The patent merges multiple extrusion runs into a single continuous extrusion process. The multi-layer liner with pigmented layers is formed in one operation by adding pigments to the extruder feed, eliminating the need for sequential extrusion runs and adhesive bonding steps. This dramatically improves manufacturing efficiency while maintaining precise color matching across all layers.
Solution Approach 2:
The pigment incorporation is performed preliminarily during the feed preparation stage, before extrusion. By pre-mixing pigments with the polymer material and feeding the combined mixture to the extruder, the system ensures uniform color distribution from the start, eliminating the need for subsequent color correction or matching operations that would require additional processing time.
4Quantity of substance
If conventional pigmented liners are used, then color can be incorporated, but scratches and defects in the liner surface are readily visible, leading to premature wearing and excessive wear appearance
Solution Approach 1:
The patent applies different properties to different parts of the liner structure. The outer surface layer is formulated with specific pigment concentrations and particle sizes that provide color while creating a surface texture or optical effect that masks scratches and surface defects. This local modification of surface quality reduces the visibility of wear and scratches without affecting the overall pigment incorporation in the liner.
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 approach reduces manufacturing costs, improves color uniformity, and enhances the liner's resistance to scratches and wear, providing a more efficient and cost-effective production process while maintaining desired color and aesthetic qualities.
Implementation Method 1
mixing a polymeric capping layer precursor and a pigment additive to form a color capping layer
Implementation Method 2
extruding a polymeric base resin to form a polymeric base layer at a base layer formation temperature
Implementation Method 3
laminating the polymeric base layer and the color capping layer to form the liner at about the base layer formation temperature
Implementation Method 4
laminating the polymeric base layer and the color capping layer to form the liner at about the base layer formation temperature, wherein the lamination is performed in the absence of an adhesive
Data Source
AI summary
A method of making a liner for an appliance is provided. The method includes mixing a polymeric capping layer precursor and a pigment additive to form a color capping layer. The method also includes extruding a polymeric base resin to form a polymeric base layer at a base layer formation temperature. The method further includes laminating the polymeric base layer and the color capping layer to form the liner at about the base layer formation temperature.