Double-Molded Washing Machine Door Cover Without Plating
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Solution Overview
Problem
Conventional washing machine door manufacturing processes generate harmful environmental contaminants and incur high costs due to post-processing methods like color spraying and chromium plating, which are used to enhance design aesthetics.
Innovation Solution
The washing machine door features a door cover made by double injection molding with a transparent outer frame and an opaque inner frame, where the frames are made of specific materials like PMMA and ABS, respectively, and are designed to scatter light, creating a metallic appearance without the need for additional post-processing, thus simplifying the manufacturing process and reducing environmental impact.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Shape
If post-processing methods like color spraying and chromium plating are used to enhance design aesthetics, then the design aesthetics of the door cover is improved, but harmful wastewater and environmental contaminants are generated and manufacturing costs increase
Solution Approach 1:
The patent changes the material parameters by using transparent materials (PMMA, PC) for the first frame and opaque materials (ABS) for the second frame, eliminating the need for post-processing color applications. The double injection molding process creates different optical properties (transparency/opacity) that provide aesthetic differentiation without harmful chemicals.
Solution Approach 2:
The patent uses composite materials with different optical properties - transparent PMMA/PC for the outer frame and opaque ABS for the inner frame. This combination creates visual contrast and aesthetic appeal through material properties rather than post-applied coatings, eliminating harmful wastewater generation.
2Shape
If post-processing methods like color spraying and chromium plating are used to enhance design aesthetics, then the design aesthetics of the door cover is improved, but manufacturing costs increase
Solution Approach 1:
The patent merges the aesthetic differentiation function into the molding process itself by using double injection molding. The first and second frames are molded in sequence, integrating what would traditionally require separate post-processing steps into a single manufacturing operation, thereby reducing costs.
Solution Approach 2:
The patent performs preliminary action by incorporating the aesthetic design features directly into the molding process. The transparent and opaque materials are applied in the correct sequence during double injection molding, eliminating the need for subsequent color spraying or plating operations.
3Shape
If a transparent outer frame and opaque inner frame are used to create design aesthetics, then design aesthetics is enhanced, but the manufacturing process complexity increases
Solution Approach 1:
The patent applies the nested doll principle by placing the second frame (inner frame) inside the first frame (outer frame) through sequential injection molding. The mold structure nests the second injection process within the first, creating a complex aesthetic design through a systematic multi-step molding process rather than separate assembly operations.
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 enhances design aesthetics while reducing manufacturing costs and environmental harm by eliminating the need for harmful post-processing methods, providing a cost-effective and eco-friendly approach to producing washing machine doors.
Implementation Method 1
a first frame which is arranged outside the door cover and made of a transparent material such that light penetrates through the first frame
Implementation Method 2
a door cover of which is formed by double injection molding
Data Source
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AI summary
A washing machine (1) includes a cabinet (10) defining an external appearance thereof and having an insertion port (11), a tub (20) arranged inside the cabinet and capable of accommodating wash water, a drum (30) arranged inside the tub and capable of accommodating laundry, and a door (100) to open and close the insertion port, and the door includes a door cover (110) including a first section (111) comprising a transparent or translucent material through which light penetrates, and a second section (112) comprising an opaque material formed such that at least a portion of the second section is visible through the first section. Therefore, manufacturing costs of the door may be reduced without the need for post-processing, and it may be possible to provide the eco-friendly washing machine having pleasing design aesthetics.