According to the statistics released by the China Household Electrical Appliances Association, the amount of plastic used in household appliances has accounted for 40% of the weight ratio, and the average usage of household appliances such as color TVs and air conditioners is 1.5-2.5 kg per unit. Plastics have become the fastest growing material in the field of home appliances, and plastic products have become an important feature of the home appliance industry.
With the change of the consumption concept in the Chinese market, more and more middle-class people are willing to choose high-end products, and the renewal cycle of home appliances is also shortening. Household appliances are developing in the direction of comfort, beauty, health and environmental protection, shock absorption and noise reduction, human-computer interaction and artificial intelligence. Therefore, home appliance plastics and processing technology will also focus on high quality, beautiful, healthy and environmentally friendly, plastic-made steel, easy processing, Lightweight and intelligent manufacturing development. So how does the innovation in the application and processing technology of plastic materials keep up with the changing pace of the industry? What high-performance plastics and processes will be “big-handed†in the home appliance market in the future?
From simple functional to high quality look and feel
With the continuous improvement of people's living standards, home appliances are not only functional products, but also gradually have "artistic qualities." The color of home appliances is no longer limited to black and white, it tends to be rich in color changes, evoking people's happiness in life; the design tends to be more dynamic, compared to the hard straight lines, making people feel friendly, relaxed and warm . This requires that the plastic parts of household appliances have both functional and functional characteristics.
The popular "smart home" concept not only promotes the development of innovative home appliances, but also raises the standards for its materials. For example, in the case of Casa Di, as the highly-recognized high-end home appliance brand of Haier Group, Casa Di has always wanted to find a high-quality innovative material for its high-end air conditioner, in order to fully reflect the artistic texture and brand difference of Casa Di. . In the past, the Casadi design team relied mainly on metals to meet performance and aesthetic requirements, but metals such as aluminum often required a combination of complex surface treatments such as sand blasting, wire drawing and anodizing, from an innovative standpoint. Traditional materials such as metals have become increasingly difficult to break through. At this time, the continuous fiber reinforced thermoplastic composite (CFRTP) developed by Covestro Polymers (China) Co., Ltd. provided the perfect solution for Casa Di. This future-oriented composite material consists of continuous carbon fiber or glass fiber. Made of polycarbonate, from the very beginning, CFRTP can form a natural one-way texture without the need for complicated processing. CFRTP gives air conditioners a high-grade metal texture and a stylish appearance. In March 2018, Casa Di launched the Tianyi air conditioner using the latest "zoned air supply" technology. It is designed with two independent air supply systems. The whole machine panel is made of CRISTP, which is unique to carbon fiber. The texture fully demonstrates the elegant artistic appearance and craftsmanship represented by the Casa di brand.
It is understood that the thermoplastic-based CFRTP can be autoclaved using existing thermoforming equipment, which has the advantages of high production efficiency and short production cycle. They can be combined with a variety of coatings and decorative processes to create unique surfaces, logos and other iconic details, and it is easy to achieve laser etched patterns directly in the mold. In general, composites are considered too expensive and difficult to process, but the CFRTP materials provided by Covestro are subversive, creating a new and exciting new, cost-effective and easy-to-form thermoplastic composite. Design possibilities and user experience.
As home appliance companies pay more and more attention to product design, CMF is not a new word in the home appliance industry. In addition to increasing technology research and development, home appliance companies must increase the design innovation of CMF, namely Color, Material and Finishing. Products with a stylish appearance, novel style and colorful colors are more easily accepted by the public. The use of environmentally friendly materials not only can decorate the appearance of the product, but also increase the functions of easy cleaning, antibacterial and anti-mildew. Through special treatment, the home appliance can have better light aging and scratch resistance, and make the product appear stronger. The texture and texture. CMF not only optimizes product design, but also promotes brand marketing and enhances product experience, helping home appliances stand out in the fierce market competition.
Consumption upgrades drive health and environmental protection demand growth
As consumers' awareness of healthy consumption has increased, clean and antibacterial household appliances have become increasingly popular, and home appliance manufacturers have put forward higher requirements for the antibacterial and bactericidal properties of plastics. It is reported that more and more companies have used antibacterial plastics in air conditioners, refrigerators, washing machines, water dispensers, rice cookers and air fresheners to reduce microbial contamination and cross-infection of germs.
The core of the development of antimicrobial plastics is the addition of antimicrobial agents to plastics. Traditional home appliances have beautiful appearances and patterns of plastic appearance parts, most of which are sprayed with paint, which leads to a large number of VOC (volatile organic compounds) emissions, which are extremely harmful to the environment, the health of first-line production employees and consumers. . As the national environmental protection policy becomes more stringent and consumers continue to upgrade their product appearance requirements, the demand for environmentally friendly and beautiful plastic products is more urgent. The “paint-free plastics with internal repair and environmental protection†has become a highlight. The material is a plastic formed by injection molding and extrusion, which can well solve the problem of flow marks and weld lines encountered in the plastic molding process, and greatly improve the appearance and texture of the plastic products, and has a disposable spray-free and beautiful appearance. Advantages such as environmental protection and low cost, and it can bring creative appearance effects that cannot be achieved by spraying, such as imitation metal, imitation glass, imitation marble and the like. At present, domestic large-scale material modification enterprises are almost all researching, producing and selling such spray-free plastics, and have successfully applied them to air conditioners, washing machines, small household appliances and other products. At present, first-line home appliance companies have begun to replace high-cost, high-pollution spray processes with metallic, pearlescent, and gradient-free spray-free plastics.
On the other hand, “furniture†of home appliances, that is, home appliances are gradually blending with the decoration style of houses, which makes home appliances that are integrated with furniture color design more popular with consumers, and spray-free plastic is also a good choice. Some domestic modified materials companies cooperate with industrial design companies to provide color pattern customization services for home appliance enterprises, and also provide metal-free texture, rhyming effect, luminous effect and other spray-free plastics to help home appliances achieve "furniture".
Use the process to solve the "high face value" and lightweight problems
How to help home appliances achieve "high value" and lightweight demand has always been a big problem in this industry. Many injection molding solution suppliers have given positive responses. For example, Guangdong Yizumi launched the FoamPro process based on MuCell's original micro-foaming technology last year. On the one hand, the FoamPro process can achieve light weight, compared with the traditional injection molding process, the weight loss is 20%, the molding cycle is shortened by 30%, the production efficiency is greatly improved, the clamping force is reduced by 50%, and the problems of warpage and shrinkage are eliminated. Home appliances and other industries produce high-quality products, including high-gloss, matte, leather, fiber-woven, and granule effects, without pressure retention and good thermal insulation. On the other hand, FoamPro micro-foaming process innovation combines a number of “black technologyâ€: SmartClamp intelligent clamping system for two-plate injection molding machine, aviation-grade aluminum alloy mold technology, ATT mold temperature control technology, FLEXflow servo needle valve hot runner system Breaking through the process bottleneck of micro-foaming.
Automation and intelligent manufacturing help industrial transformation and upgrading
The labor cost is rising, the management difficulty of the younger generation of industrial workers is increasing, and there is a “labor shortage†every year, which forces the company to seek transformation, and factory automation is a good thing for the home appliance manufacturing industry. solution. In addition, with the gradual decline of automation equipment costs and the continuous expansion of robot downstream applications, today, the transformation to high-end, intelligent transformation has become the consensus of the entire home appliance industry chain, Haier, Midea, Skyworth, Galanz, Gree, Hisense, etc. Home appliance companies are using a large number of automation equipment or robots, and they are looking for “intelligent†upgrade solutions for unmanned automated production, equipment interconnection and visualization in the workshop to improve the production and operation efficiency and manufacturing quality of home appliance enterprises.
Spray-free plastic helps home appliances achieve "furniture"
Now, in the face of the pressure of falling profits, the requirements for molding equipment for plastic parts processing and production enterprises located in the upstream of the home appliance industry chain involve multiple aspects: energy saving and emission reduction, and automation, to reduce manpower and production time, and reduce Production costs make products more competitive in the market. Dongguan Hongda Electrical Products Co., Ltd. is the production base of Miele, a top brand of German household appliances, based in mainland China. It mainly produces household vacuum cleaners. Hongda currently uses five injection molding machines supplied by a well-known injection molding machine brand to produce different vacuum cleaner parts. The relevant person in charge of Hongda said that the reason why the company's injection molding machine series is used, in addition to the machine is very energy-efficient, it also helps itself to further automation. In fact, the hydraulic injection molding machine produced by the above-mentioned injection molding machine manufacturers is very suitable for the routine application of mass production. This application does not require special technology, and can effectively improve the quality and process, and produce the parts. No need for follow-up processing, saving time and manpower.
The transformation and upgrading of the labor-intensive industry, which is the production of plastic parts, is imminent, but some injection molding enterprises have certain deviations from the understanding of intelligent manufacturing. They think that accessing the ERP system, or monitoring the injection molding machine, even adding several robots and automatic belt lines, etc. Achieve smart manufacturing. In fact, only the people, machines, materials, products and data distribution can be fully integrated to lay the foundation for intelligent manufacturing.
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