# US 11,306,965 B2 · Hybrid pigmented hot stitched color liner system

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- Number: US 11,306,965 B2
- Document ID: US11306965B2
- Status: Granted
- Kind: B2
- Application number: 17/137,578
- Filed: 2020-12-30
- Published: 2021-04-22
- Granted: 2022-04-19
- Earliest claimed: 2018-06-25
- Assignees: Whirlpool Corporation
- Applicants: Whirlpool Corporation
- Inventors: Vincent D. Csapos; Mario J. Godinho; Muhammad Khizar
- Web page: https://patentgrep.com/patent/US11306965B2

## CPC

- B29C 69/00: Combinations of shaping techniques not provided for in a single one of main groups B29C39/00 - B29C67/00, e.g. associations of moulding and joining techniques; Apparatus therefore {(B29C48/001 takes precedence)}
- F25D 23/066: {Liners}
- B29C 69/02: of moulding techniques only
- B32B 5/18: characterised by features of a layer {of} foamed material
- B32B 7/12: using interposed adhesives or interposed materials with bonding properties
- B32B 27/065: {of foam}
- B32B 27/08: of synthetic resin
- B32B 27/20: using fillers, pigments, thixotroping agents
- B32B 27/302: {comprising aromatic vinyl (co)polymers, e.g. styrenic (co)polymers}
- B32B 27/32: comprising polyolefins {(comprising vinyl (co)polymers or acrylic (co)polymers B32B27/30)}
- B32B 27/34: comprising polyamides
- B32B 27/36: comprising polyesters
- B32B 27/365: {comprising polycarbonates}
- B32B 27/40: comprising polyurethanes
- B29C 43/02: of articles of definite length, i.e. discrete articles {(B29C35/0227 takes precedence)}
- B29C 43/24: Calendering
- B29C 43/305: {Making multilayered articles}
- B29C 48/0011: {combined with compression moulding}
- B29K 2023/06: {PE, i.e. polyethylene}
- B29K 2025/06: {PS, i.e. polystyrene}
- B29K 2067/003: {PET, i.e. poylethylene terephthalate}
- B29K 2995/002: Coloured
- B29K 2995/0067: non-permeable
- B29L 2031/7622: {Refrigerators}
- B32B 2250/03: 3 layers
- B32B 2250/04: 4 layers
- B32B 2264/10: Inorganic particles
- B32B 2264/102: Oxide or hydroxide
- B32B 2264/105: Metal
- B32B 2264/108: Carbon, e.g. graphite particles
- B32B 2266/06: Open cell foam
- B32B 2266/08: Closed cell foam
- B32B 2270/00: Resin or rubber layer containing a blend of at least two different polymers
- B32B 2307/4026: within the layer by addition of a colorant, e.g. pigments, dyes
- B32B 2307/406: Bright, glossy, shiny surface
- B32B 2307/554: Wear resistance
- B32B 2307/584: Scratch resistance
- B32B 2307/7242: Non-permeable
- B32B 2307/732: Dimensional properties
- B32B 2509/10: Refrigerators or refrigerating equipment
- F25D 2400/18: Aesthetic features
- B29C: SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING (making preforms B29B11/00; making laminated products by combining previously unconnected layers which become one product whose layers will remain together B32B37/00 - B32B41/00)
- F25D: REFRIGERATORS; COLD ROOMS; ICE-BOXES; COOLING OR FREEZING APPARATUS NOT OTHERWISE PROVIDED FOR (refrigerated showcases A47F3/04; thermally-insulated vessels for domestic use A47J41/00; refrigerated vehicles, see the appropriate subclasses of classes B60 - B64; containers with thermal insulation in general B65D81/38; heat-transfer, heat-exchange or heat-storage materials, e.g. refrigerants, or materials for the production of heat or cold by chemical reactions other than by combustion C09K5/00; thermally-insulated vessels for liquefied or solidified gases F17C; air-conditioning or air-humidification F24F; refrigeration machines, plants, or systems F25B; cooling of instruments or comparable apparatus without refrigeration G12B)
- B32B: LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
- B29K: INDEXING SCHEME ASSOCIATED WITH SUBCLASSES B29B, B29C OR B29D, RELATING TO MOULDING MATERIALS OR TO MATERIALS FOR {MOULDS, } REINFORCEMENTS, FILLERS OR PREFORMED PARTS, e.g. INSERTS
- B29L: INDEXING SCHEME ASSOCIATED WITH SUBCLASS B29C, RELATING TO PARTICULAR ARTICLES

## Abstract

A method of making a liner for an appliance is provided. The method includes mixing a polymeric capping layer precursor and a pigment additive to form a color capping layer. The method also includes extruding a polymeric base resin to form a polymeric base layer at a base layer formation temperature. The method further includes laminating the polymeric base layer and the color capping layer to form the liner at about the base layer formation temperature.

## Claims

### Claim 1

A method of making a liner for an appliance, the method comprising:
mixing a polymeric capping layer precursor and a pigment additive to form a color capping layer such that a pigment concentration in the color capping layer is at least about 10% by weight, wherein a thickness of the color capping layer is in a range of about 0.60 mm to about 0.80 mm;
extruding a polymeric base resin to form a polymeric base layer at a base layer formation temperature, wherein a thickness of the polymeric base layer is greater than the thickness of the color capping layer; and
laminating the polymeric base layer and the color capping layer to form the liner at about the base layer formation temperature.

### Claim 2 (depends on 1)

The method of claim 1, wherein the thickness of the color capping layer is in the range of about 0.70 mm to about 0.80 mm.

### Claim 3 (depends on 2)

The method of claim 2, wherein the thickness of the color capping layer is in the range of about 0.75 mm to about 0.80 mm.

### Claim 4 (depends on 1)

The method of claim 1, further comprising:
mounting the liner to a foam layer of the appliance.

### Claim 5 (depends on 1)

The method of claim 1, further comprising:
mounting the liner to a cabinet of the appliance.

### Claim 6 (depends on 1)

The method of claim 1, wherein the step of laminating the polymeric base layer and the color capping layer to form the liner at about the base layer formation temperature is performed in the absence of an adhesive.

### Claim 7 (depends on 1)

The method of claim 1, wherein the polymeric base layer comprises from about 1% to about 30% of the pigment additive by weight.

### Claim 8 (depends on 1)

The method of claim 1, wherein the base layer formation temperature is in a range of about 120° C. to about 160° C.

### Claim 9 (depends on 1)

The method of claim 1, wherein the mixing step is conducted with an extruder.

### Claim 10 (depends on 1)

The method of claim 1, wherein the laminating step is conducted with one or more calendaring rollers.

### Claim 11 (depends on 1)

The method of claim 1, further comprising:
forming a textured pattern on an outer surface of the color capping layer.

### Claim 12 (depends on 1)

The method of claim 1, further comprising:
shaping the liner into a final liner at a shaping temperature.

### Claim 13 (depends on 12)

The method of claim 12, wherein the final liner is suitable for assembly into a refrigeration appliance.

### Claim 14 (depends on 1)

The method of claim 1, wherein the thickness of the polymeric base layer is at least 50% greater than the thickness of the color capping layer.

### Claim 15

A method of making a liner for an appliance, the method comprising:
mixing a polymeric capping layer precursor and a pigment additive to form a color capping layer such that a pigment concentration in the color capping layer is at least about 10% by weight, wherein a thickness of the color capping layer is in a range of about 0.60 mm to about 0.80 mm;
extruding a polymeric base resin to form a polymeric base layer at a base layer formation temperature, wherein a thickness of the polymeric base layer is greater than the thickness of the color capping layer; and
laminating the polymeric base layer and the color capping layer to form the liner at about the base layer formation temperature, wherein the lamination is performed in the absence of an adhesive.

### Claim 16 (depends on 15)

The method of claim 15, wherein the thickness of the color capping layer is in the range of about 0.70 mm to about 0.80 mm.

### Claim 17 (depends on 16)

The method of claim 16, wherein the thickness of the color capping layer is in the range of about 0.75 mm to about 0.80 mm.

### Claim 18 (depends on 15)

The method of claim 15, further comprising:
mounting the liner to a foam layer of the appliance.

### Claim 19 (depends on 15)

The method of claim 15, wherein the thickness of the polymeric base layer is at least 50% greater than the thickness of the color capping layer.

### Claim 20 (depends on 15)

The method of claim 15, wherein the base layer formation temperature is in a range of about 120° C. to about 160° C.