Co-Injected Appliance Components with Recycled Core and Virgin Skin

Solution Overview

Problem

Components for water-bearing appliances made from recycled plastic often compromise on both aesthetic appearance and mechanical properties, and current methods do not effectively reduce production costs or environmental impact.

Innovation Solution

Aesthetic components for laundry or dish washing machines are created using a combination of a non-recycled polymeric material as the external layer and a recycled polymeric material as the core, with the two materials forming a one-piece monolithic body through a co-injection moulding process, optimizing both aesthetics and mechanical properties while reducing material consumption and environmental impact.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Ease of manufacture

If recycled plastic material is used to produce components, then production cost is reduced and environmental impact is minimized, but aesthetic appearance and mechanical properties are worsened

Engineering Contradiction:

Improveproduction costVSAvoidmechanical properties

Core Design Contradiction:

Ease of manufactureVSStrength

Solution Approach 1:

The component is divided into multiple layers with different material compositions. The first layer (external surface) uses virgin polymeric material for aesthetic and mechanical performance, while the second layer (internal core) uses recycled polymeric material for cost-effectiveness and environmental benefits. This segmentation allows each layer to fulfill its specific functional requirements independently.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

Different regions of the component have different material qualities tailored to their specific functions. The external surface layer has high aesthetic quality and mechanical strength using virgin material, while the internal core has adequate mechanical properties using recycled material. Each local region's material quality is optimized for its specific role in the component.

Inventive Principle:

Principle #3Local quality

2Ease of manufacture

If recycled plastic material is used to produce components, then production cost is reduced and environmental impact is minimized, but aesthetic appearance is worsened

Engineering Contradiction:

Improveproduction costVSAvoidaesthetic appearance

Core Design Contradiction:

Ease of manufactureVSShape

Solution Approach 1:

The component is divided into multiple layers with different material compositions. The first layer (external surface) uses virgin polymeric material for aesthetic and mechanical performance, while the second layer (internal core) uses recycled polymeric material for cost-effectiveness and environmental benefits. This segmentation allows each layer to fulfill its specific functional requirements independently.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

Different regions of the component have different material qualities tailored to their specific functions. The external surface layer has high aesthetic quality and mechanical strength using virgin material, while the internal core has adequate mechanical properties using recycled material. Each local region's material quality is optimized for its specific role in the component.

Inventive Principle:

Principle #3Local quality

3Strength

If virgin polymeric material is used for the entire component, then aesthetic appearance and mechanical properties are improved, but production cost increases and environmental impact worsens

Engineering Contradiction:

Improvemechanical propertiesVSAvoidproduction cost

Core Design Contradiction:

StrengthVSEase of manufacture

Solution Approach 1:

The component is divided into multiple layers with different material compositions. The first layer (external surface) uses virgin polymeric material for aesthetic and mechanical performance, while the second layer (internal core) uses recycled polymeric material for cost-effectiveness and environmental benefits. This segmentation allows each layer to fulfill its specific functional requirements independently.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

Different regions of the component have different material qualities tailored to their specific functions. The external surface layer has high aesthetic quality and mechanical strength using virgin material, while the internal core has adequate mechanical properties using recycled material. Each local region's material quality is optimized for its specific role in the component.

Inventive Principle:

Principle #3Local quality

4Shape

If virgin polymeric material is used for the entire component, then aesthetic appearance is improved, but production cost increases and environmental impact worsens

Engineering Contradiction:

Improveaesthetic appearanceVSAvoidproduction cost

Core Design Contradiction:

ShapeVSEase of manufacture

Solution Approach 1:

The component is divided into multiple layers with different material compositions. The first layer (external surface) uses virgin polymeric material for aesthetic and mechanical performance, while the second layer (internal core) uses recycled polymeric material for cost-effectiveness and environmental benefits. This segmentation allows each layer to fulfill its specific functional requirements independently.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

Different regions of the component have different material qualities tailored to their specific functions. The external surface layer has high aesthetic quality and mechanical strength using virgin material, while the internal core has adequate mechanical properties using recycled material. Each local region's material quality is optimized for its specific role in the component.

Inventive Principle:

Principle #3Local quality

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 enhances the aesthetic appeal and mechanical performance of components while minimizing production costs and environmental impact by utilizing recycled materials within specific impurity thresholds, ensuring effective re-use and recycling of waste plastics.

Implementation Method 1

injecting from at least one injection point said first polymeric material into a cavity of a mould for a first time so that said first polymeric material reaches internal surfaces of said mould and at least partially solidifies to form an external solidified layer

Methodology Applied

Scientific EffectInjection moulding:

Implementation Method 2

injecting from said at least one injection point, after said first time, said second polymeric material into said mould for a second time so that said second polymeric material fills the core of said cavity and pushes the first polymeric material not jet solidified

Methodology Applied

Scientific EffectCo-injection moulding:

Implementation Method 3

said first polymeric material reaches internal surfaces of said mould and at least partially solidifies to form an external solidified layer

Methodology Applied

Scientific EffectSolidification: Freezing

Data Source

PatentUS20230103869A1Component for a water bearing appliance and method for producing such component

Publication Date: 2023.04.06 ELECTROLUX APPLIANCES

AI summary

An aesthetic component for a water bearing appliance. The component comprises a first polymeric material and a second polymeric material. The external surface of the component is at least partially constituted by the first polymeric material and the first polymeric material covers the second polymeric material. The second polymeric material comprises a recycled polymeric material.