Pigmented monolayer liner for appliances and methods of making the same
Solution Overview
Problem
Conventional methods for producing pigmented liners for appliances, especially refrigeration applications, face challenges with complexity, cost, and reliability due to multi-layer extrusion processes, which require multiple extrusion runs, adhesives, and can result in discoloration and yield losses.
Innovation Solution
A method involving a polymeric capping layer precursor and pigment additive, formed into a capping layer at a specific temperature, is rolled with a polymeric base layer to create a monolayer liner with no interfaces, eliminating the need for internal adhesives and allowing for high-impact polystyrene materials throughout, ensuring color consistency and reduced manufacturing costs.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If pigments are added to multiple extruders to produce multi-layer pigmented liners, then color variety is achieved, but manufacturing complexity and cost increase significantly
Solution Approach 1:
The patent divides the liner into a base layer and a capping layer, with pigments concentrated in the capping layer. This segmentation allows color variety to be achieved by modifying only the capping layer composition, rather than modifying multiple extruders, thereby reducing manufacturing complexity while maintaining color adaptability.
Solution Approach 2:
The patent applies local quality by concentrating pigment additives specifically in the capping layer region rather than distributing them uniformly throughout all layers. This localized pigment placement enables color customization through single-extruder capping layer production, simplifying the manufacturing process while achieving diverse color options.
2Illumination intensity
If significant loadings of pigments are employed in multi-layer liners, then color intensity is achieved, but downstream processes lead to local discoloration and yield losses
Solution Approach 1:
The patent performs preliminary action by forming the capping layer with pigments at a specific formation temperature, then rolling it into the base layer while maintaining that temperature. This temperature control during the rolling process prevents pigment degradation and discoloration that would otherwise occur during downstream thermo-forming operations, thereby maintaining color uniformity while achieving intense coloration.
3Manufacturing precision
If multiple extrusion runs are required to fabricate pigmented multi-layer liners, then color matching precision is achieved, but manufacturing time and cost increase
Solution Approach 1:
The patent merges the base layer and capping layer production into a single continuous rolling operation. The capping layer is formed with pigments at a specific temperature and then immediately rolled into the base layer at the same temperature, eliminating the need for multiple separate extrusion runs. This combining of operations maintains color matching precision while dramatically improving manufacturing efficiency.
4Strength
If adhesives are used to bond layers in multi-layer liners, then layer bonding strength is achieved, but manufacturing cost increases and yield decreases
Solution Approach 1:
The patent employs self-service by designing the capping layer and base layer with complementary surface properties that enable them to bond to each other through the rolling process without requiring external adhesives. The thermal and mechanical conditions during rolling create sufficient adhesion between layers, eliminating the need for additional adhesive materials and associated manufacturing complexity.
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 results in a cost-effective, reliable, and aesthetically flexible pigmented liner with improved color uniformity and reduced manufacturing complexity, suitable for various design aesthetics without the need for internal adhesives.
Implementation Method 1
forming the capping layer precursor and the pigment additive into a capping layer at a capping layer formation temperature
Implementation Method 2
rolling the capping layer into a polymeric base layer to form a liner
Data Source
AI summary
A method of making a liner for an appliance is provided that includes: mixing a polymeric capping layer precursor and a pigment additive; forming the capping layer precursor and the pigment additive into a capping layer at a capping layer formation temperature; and rolling the capping layer, a barrier layer and a polymeric base layer together to form a liner, each of the capping layer, the barrier layer and the base layer at about the capping layer formation temperature. Further, the liner comprises a capping region, a barrier region and a base region, the capping region comprising the pigment additive.