Two-Layer Injection-Molded Display Surface Element for Durable Opacity
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
The production of display surface elements for ovens is complex and expensive due to the fragility of thin printed layers, which can be damaged by scratches or abrasion, and requires multiple printing and drying processes, while conventional printed glass plates need additional fasteners for attachment.
Innovation Solution
A one-piece display surface element composed of two molecularly connected layers of homogeneous material components, produced via injection molding, with thicknesses in the millimeter range to ensure durability and integrated structural elements for secure attachment, and matching thermal expansion properties to prevent mechanical stress.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If thin printed layers are used to create opaque areas on glass plates, then the display surface element can be made with conventional materials and processes, but the printed layers are easily damaged by scratches or abrasion leading to transparent areas and require multiple printing and drying processes
Solution Approach 1:
The patent changes the thickness parameter of the opaque layer from conventional thin printed layers (micrometer range) to injection-molded layers (millimeter range, at least 0.5 mm). This parameter change makes the layer resistant to scratches and abrasion while maintaining the ability to be manufactured in one piece with integrated structural elements, resolving the contradiction between manufacturing simplicity and opacity durability.
Solution Approach 2:
The patent uses composite material construction with at least two different material components: a transparent material for the transparent areas and an opaque material for the opaque areas including structural elements. This composite approach allows both materials to be injection-molded together in one piece, eliminating the need for separate printing processes while ensuring the opaque areas remain durable and scratch-resistant.
2Manufacturing precision
If multiple printing and drying processes are used to create opaque areas, then the display surface element can achieve the required opacity, but the production becomes complex and expensive
Solution Approach 1:
The patent merges the creation of opaque areas with the structural elements into a single injection molding process. The opaque layer and structural elements (such as mounting tabs or connection parts) are formed simultaneously as one integrated piece, eliminating the need for separate printing and drying processes while ensuring precise opacity quality and reducing production complexity.
Solution Approach 2:
The patent replaces the chemical printing and drying processes with a mechanical injection molding process. Instead of applying and drying liquid printing materials, the opaque layer is formed by injecting molten opaque material into a mold, which eliminates the complexity of multiple printing and drying steps while maintaining high manufacturing precision for the opaque areas.
3Ease of manufacture
If conventional printed glass plates are used, then the display surface element can be manufactured with standard materials, but additional fasteners are required for attachment to the household appliance
Solution Approach 1:
The patent merges the functional opaque layer with the structural attachment elements into a single integrated component. The structural elements (such as mounting tabs or connection protrusions) are injection-molded directly into the opaque layer, eliminating the need for separate fasteners and reducing the total number of components while maintaining ease of manufacture using standard injection molding techniques.
Solution Approach 2:
The patent makes the opaque layer multi-functional by integrating both the display function (providing opaque areas for indicators) and the structural attachment function (providing mounting elements) into a single component. This universal design eliminates the need for additional fasteners and simplifies the overall assembly process while maintaining material availability through standard injection molding materials.
4Strength
If thermal process steps are used to produce display surface elements, then the layers can be molecularly connected, but thermally induced mechanical stresses may change the predetermined shape due to different expansion behavior of material components
Solution Approach 1:
The patent changes the material selection parameters by choosing material components with matched thermal expansion coefficients. This parameter change allows the different materials (transparent and opaque) to expand and contract at similar rates during thermal processing, preventing thermally induced mechanical stresses that would otherwise distort the predetermined shape, while still achieving strong molecular bonding through the thermal process.
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 solution simplifies production, enhances durability by preventing opacity impairment from abrasion, eliminates the need for additional fasteners, and allows for integrated structural elements and embedded display elements, reducing manufacturing costs and improving reliability.
Implementation Method 1
molecularly connected to one another by means of thermal energy, preferably in an injection molding process
Implementation Method 2
different expansion behavior of the material components
Data Source
AI summary
The display surface element (5) consists of a one-piece plate which has transparent and opaque plate areas. According to the invention, the plate is formed from at least two intimately connected layers (1, 2) of the same type, of which at least one layer (1) is transparent and a second layer (2) has at least partially opaque areas.