KT punching process for double-color ear cap

Abstract

The double-color ear cap KT punching technology comprises the following steps that S1, a mold with an adjustable temperature control system and a dynamic runner structure is provided, and the mold comprises a first injection molding cavity and a second injection molding cavity; s2, designing an internal structure of the ear cap by using a three-dimensional design tool, adjusting key parameters through a Bayesian optimization algorithm, manufacturing the internal structure by using a nano-resolution 3D printing technology, and positioning through an automatic alignment system; s3, a plastic material of the first color is injected into the first injection molding cavity, and a first part of the ear cap is formed; s4, the ear cap part is transferred to a second injection molding cavity through an automatic alignment system; s5, injecting a plastic material with a second color to form a second part of the ear cap; s6, performing multifunctional surface treatment on the ear caps; s7, complex patterns and textures are formed on the surfaces of the ear caps through the KT technology, and the uniqueness and high quality of the appearance are ensured; s8, carrying out quality detection; s9, the ear caps are packaged, and anti-fake intelligent labels are added; the quality of the ear cap and the user experience are improved.

Description

Technical Field

[0001] The present invention relates to the technical field of earphone accessories manufacturing, in particular to a KT process for double-color ear caps. Background Art

[0002] With the increasing popularity of consumer electronics, especially smartphones and tablets, earphones, as a key accessory for these devices, are experiencing increasing market demand year by year. As a crucial component of earphones, ear caps directly contact the user's ear canal, making their comfort, durability, hygiene, and design particularly important. Traditional ear cap manufacturing typically utilizes a single-color injection molding process. While this process meets basic usage requirements, it struggles to meet the growing market demand for personalized and functional features.

[0003] The existing manufacturing process of two-color ear caps is usually achieved through secondary injection molding, that is, the first color of material is injection-molded in the mold, and then the second color of material is injected into the same mold or transferred to another mold to finally form the two-color ear caps. However, this traditional process has some obvious defects. First, in terms of material selection and process control, it is difficult for traditional processes to achieve a precise combination of materials. Secondly, the two-color injection molding process often lacks fine control over the surface pattern, logo or texture of the ear cap. Existing surface treatment methods such as ordinary laser engraving and printing technology are difficult to meet users' needs for personalized appearance of ear caps, and the durability and detail expression of the pattern are also relatively limited.

[0004] Furthermore, existing technologies also have shortcomings in the surface treatment of ear caps. Most ear caps are treated with simple antibacterial and antifouling coatings, failing to provide effective UV protection. This leads to aging and fading after prolonged use, impacting their lifespan and aesthetics. Inadequate adhesion and uniformity of the surface coating also lead to coating detachment, further reducing the durability of the ear caps.

[0005] In terms of inspection and quality control, traditional earmuff manufacturing processes typically rely on manual or simple mechanical inspection methods, making it difficult to fully inspect the earmuffs for surface finish, dimensional accuracy, and pattern clarity. This not only increases labor costs and reduces production efficiency, but also easily leads to missed or false inspections, affecting the quality consistency of the final product.

[0006] In summary, the existing two-color ear cap manufacturing process has a series of problems such as weak material bonding, poor surface treatment effect, insufficient personalized design and imperfect quality inspection, which cannot meet the market demand for high-quality ear caps.

[0007] Therefore, how to provide a two-color ear cap KT process is a problem that those skilled in the art urgently need to solve. Summary of the Invention

[0008] One objective of this invention is to propose a KT process for two-color ear caps. This process combines advanced injection molding, 3D printing, surface treatment, and optical inspection technologies, detailing the steps involved in forming complex patterns, logos, or textures on the surface of two-color ear caps. By utilizing a multi-objective Bayesian optimization algorithm, fractional calculus, laser transfer technology, and adaptive photoacoustic laser engraving, this process offers the advantages of high precision, durability, and customization, significantly improving the overall quality and user experience of the ear caps and meeting market demand for high-quality ear caps.

[0009] The KT process for printing two-color ear caps according to an embodiment of the present invention includes the following steps:

[0010] S1. Provide a mold with an adjustable temperature control system and a dynamic flow channel structure, the mold comprising a first injection cavity and a second injection cavity;

[0011] S2. Use 3D printing technology to manufacture the internal structure of the ear cap. After printing, automatically inspect the internal structure using a 3D surface detection algorithm. Place the qualified internal structure of the ear cap into the first injection cavity of the mold and position it using an automatic alignment system based on quantum particle swarm optimization.

[0012] S3, injecting a plastic material of a first color into a first injection cavity, and forming a first part of the ear cap on the 3D printed internal structure through an injection molding process;

[0013] S4. After the injection molding of the first part is completed, an automatic alignment system based on a multi-dimensional nonlinear dynamic chaos algorithm is used to accurately transfer the partially molded ear cap from the first injection cavity to the second injection cavity to optimize the accuracy of the docking between the first and second parts;

[0014] S5. Injecting a second color of plastic material into a second injection molding cavity to form a second portion of the ear cap through a secondary injection molding process. Optimizing uniform material distribution through thermal-compression coupled dynamic equations to optimize the seamless integration of the second portion with the first portion. After the secondary injection molding is completed, cooling is performed using a multiphase cooling system to optimize the overall structure of the ear cap to prevent deformation or stress concentration during the curing process.

[0015] S6. Multifunctional surface treatment of the two-color ear caps, including antibacterial coating, antifouling coating and UV protection coating, to optimize the durability and hygiene performance of the ear caps;

[0016] S7. Use the KT process to form complex patterns, logos, or textures on the ear cap surface. The depth and quality of the laser engraving are described and optimized using the Kramers-Kronig relationship. After cleaning, check the surface finish.

[0017] S8. Conduct quality inspection on the two-color ear caps after surface treatment, including dimensional accuracy, wear resistance and color durability tests;

[0018] S9. The two-color ear caps that have passed the quality inspection will be packaged and a smart label with product information will be added to the package.

[0019] Optionally, the S2 specifically includes:

[0020] S21. Use a 3D design tool based on metamaterial properties and multi-scale modeling to design the internal structure of the ear cap. During the design process, a multi-objective Bayesian optimization algorithm combined with shape optimization techniques using fractional calculus was used to adjust key design parameters of the internal structure, including the skeleton thickness T, aperture D, and support position P:

[0021]

[0022] in, is the objective function, is the structural field function, α and β are the weight factors of Bayesian optimization and fractional calculus, is the gradient vector, Ω is the design space;

[0023] S22. Convert the optimized 3D model into a file suitable for nano-resolution 3D printing and import it into a selective laser melting printer. The printing material is a composite polymer with a heterogeneous nanocrystalline structure. The Young's modulus E and density ρ of the material are preprocessed using the nonlinear stress-strain relationship:

[0024]

[0025] Where σ(∈) is stress, ∈ is strain, Γ(∈) is the nonlinear gauge factor function, E0 and ρ0 are the initial Young's modulus and density of the material;

[0026] S23. Before 3D printing, the printing parameters are optimized using a deep generative adversarial network based on a co-evolutionary strategy. The deep generative adversarial network based on the co-evolutionary strategy generates a set of printing parameters, including layer thickness H, printing temperature T, and scanning speed V, through game training between the generative and discriminative networks:

[0027]

[0028] Among them, G(H,T,V) is the objective function, G(z) and D(x) are the generating network and discriminant network respectively, Ω(H,T,V) is the regularization term for printing parameter optimization, λ is the weight parameter, and p data (x) and p z (z) are data distribution and noise distribution respectively;

[0029] S24. Start the 3D printer and print layer by layer according to the printing parameter set generated by the deep adversarial generative network of the collaborative evolutionary strategy. During the printing process, a multimodal adaptive control algorithm is used to monitor and adjust the printing temperature T and material deposition speed V in real time. The temperature control equation is:

[0030]

[0031] Where k(T) is the temperature-dependent thermal conductivity, Q is the internal heat source term, and c p is the specific heat capacity, To control the coefficient, the temperature gradient and heat source terms are adjusted;

[0032] S25. After printing is completed, the internal structure is automatically inspected using a three-dimensional surface inspection algorithm that combines fractional Fourier transform and wavelet transform. During the inspection process, Fourier transform analyzes the multi-scale characteristics of surface roughness, and wavelet transform is used to optimize local details.

[0033] S26. Place the internal structure of the ear cap that has passed the multi-scale surface inspection in the first injection cavity of the mold and position it through an automatic alignment system based on quantum particle swarm optimization. The alignment process adjusts the position through the phase interference effect of the quantum superposition state.

[0034] Optionally, the S3 specifically includes:

[0035] S31, placing the internal structure of the ear cap optimized in S26 into the first injection cavity of the mold, and using the alignment system to position the internal structure to optimize the quality of subsequent injection molding;

[0036] S32. Selecting a first color plastic material suitable for injection molding, wherein the first color plastic material has a thermosensitive response characteristic and can adjust its viscosity during processing, and heating the material to a specified temperature;

[0037] S33. Start the injection molding machine and inject the heated first color plastic material into the first injection cavity of the mold. During the injection molding process, the nonlinear coupling effect formula integrating time, temperature, and shear rate optimizes the dynamic control of material fluidity and stability by considering the oscillatory response and time decay characteristics of the material during processing:

[0038]

[0039] in, is the time-varying effective viscosity of the material, η0 is the initial viscosity of the material under reference conditions, δ, α, β, λ, γ are the characteristic coefficients of the material, ω is the time-dependent oscillation frequency, T is the current material temperature, T m is the melting point temperature of the material, is the shear rate, n is the rheological index, t is the time, and τ is the time constant of the material, which describes the characteristics of the material viscosity decaying with time;

[0040] S34. After the injection molding is completed, the mold temperature is controlled by the cooling system, and the material is gradually solidified at an appropriate cooling rate to form the first part of the ear cap, thereby optimizing the reduction of stress inside the material during the solidification process;

[0041] S35. After cooling and solidification, use measuring equipment to inspect the size and surface finish of the first molded part.

[0042] Optionally, the S5 specifically includes:

[0043] S51. Remove the first part of the ear cap formed in step S3 from the first injection molding cavity and transfer it to the second injection molding cavity of the mold using an automated alignment system. During this process, an alignment system based on a multi-dimensional nonlinear dynamic chaos algorithm is used to optimize the accuracy of the docking between the first part and the second part.

[0044]

[0045] Among them, L i,1 and L i,2 denote the local lengths of the first and second parts at the joint, λ i , γ i is the nonlinear counter-position coefficient, τ i is the time constant, α, β, θ are adjustment parameters, t is the time, and N is the number of sampling points;

[0046] S52, selecting a second color plastic material with high elasticity and wear resistance, and preheating the second color plastic material to a temperature range T2 suitable for injection molding;

[0047] S53, start the injection molding machine, and inject the heated second color plastic material into the second injection cavity of the mold. The rheological behavior of the second color plastic material during the injection molding process is very complex, involving multiple physical phenomena, and the viscosity η fusion It is described by the following multivariable coupling formula:

[0048]

[0049] in, Effective viscosity after fusion η fusion , T current temperature, Shear rate, φ material interaction parameter, ω vibration frequency, η0 base viscosity, n1 and m1 rheological parameters, β1 is a dimensionless coefficient used to adjust the intensity of the effect of shear rate on viscosity, E aActivation energy of material molecular motion, R gas constant, cosh hyperbolic cosine function, cosh(x) represents the hyperbolic cosine function, which is used to describe the complex nonlinear relationship between viscosity over time, interaction force and vibration frequency, λ time-dependent parameter, α thermal expansion coefficient, T m Material melting point temperature, δ and ζ nonlinear adjustment parameters;

[0050] S54. During the injection molding process, an adaptive multi-dimensional sensing system is used to monitor the temperature and pressure distribution of the second part of the material in real time. The thermal-pressure coupling dynamic equation is used to optimize the uniform distribution of the material and seamlessly integrate it with the first part:

[0051]

[0052] in, represents the multidimensional coupled gradient of temperature and pressure, is the partial derivative of pressure P with respect to temperature T, α3 is the coupling coefficient related to the thermal properties of the material, δ and β are adjustment parameters for controlling the nonlinear response of temperature, T and time t, β2 is the pressure fluctuation coefficient, which is used to adjust the response of pressure with time and vibration frequency ω, ω is the vibration frequency, θ is the time-related adjustment parameter, which controls the coupling effect between vibration frequency and time, τ3 is the time constant, λ3 is the attenuation coefficient, which describes the gradual weakening of the effect of temperature on pressure over time, R is the gas constant, T c is the critical temperature of the material, which serves as a reference temperature to measure the effect of actual temperature on the material behavior. ζ is a temperature-dependent nonlinear adjustment parameter that regulates the effect of temperature on the coupling gradient.

[0053] S55. After the injection molding of the second part is completed, a multi-phase cooling system is used for cooling to optimize the overall structure of the ear cap so as not to cause deformation or stress concentration during the curing process.

[0054] Optionally, the S7 specifically includes:

[0055] S71. Pre-treat the surface of the ear cap after double-color injection molding. The pre-treatment includes using plasma cleaning combined with specific chemical modifiers to treat the ear cap surface. The surface energy is increased by generating functional groups. The change in surface energy is described by the Frumkin isotherm adsorption model:

[0056]

[0057] Where θ represents the surface coverage, the adsorption ratio of the modifier on the ear cap surface; K is the adsorption equilibrium constant, C is the concentration of the modifier, and a represents the interaction strength between the adsorbed molecules;

[0058] S72. After surface pretreatment, the first step of the KT process is to form a basic pattern on the ear cap surface using laser transfer technology. During the laser transfer process, the energy absorption and conversion of the material is described by the Wagner model:

[0059]

[0060] Where η represents the overpotential of the material surface under laser action, that is, the electrochemical potential difference in the energy conversion process; R is the gas constant, T is the absolute temperature, n is the number of electron transfers, F is the Faraday constant, j is the current density, and j0 is the exchange current density;

[0061] S73. After the base pattern is transferred, the pattern and text are engraved on the surface of the ear cap using laser engraving technology. The depth and quality of the laser engraving are described and optimized using the Kramers-Kronig relationship:

[0062]

[0063] Where n(ω) represents the refractive index of the material, reflecting the speed of light propagation in the material; k(ω') is the absorption coefficient, describing the material's ability to absorb light; ω and ω' are the frequencies of light;

[0064] S74. After laser engraving is completed, the ear cap surface is cleaned using a multiphase fluid dynamics cleaning model to remove small particles and chemical residues.

[0065] S75. Perform optical inspection on the surface of the ear cap to check the integrity of the pattern and text as well as the surface finish. Use optical interferometry technology, combined with S71-7S4 data, to verify whether the surface quality of the ear cap meets the design requirements.

[0066] Beneficial effects

[0067] 1. Precise Material Integration and Multifunctional Structure: This invention utilizes a mold with an adjustable temperature control system and dynamic flow channel structure, combining the properties of metamaterials with a 3D design tool for multi-scale modeling to precisely design and optimize the internal structure of the ear cap. A multi-objective Bayesian optimization algorithm and fractional calculus techniques ensure precise control of the internal structure's skeleton thickness, pore size, and support positions. This approach significantly enhances the ear cap's structural stability and functionality, enabling seamless integration of different materials during the injection molding process and overcoming the issues of weak material bonding and surface permeability associated with traditional two-color injection molding.

[0068] 2. High-Precision 3D Printing and Quality Inspection: This invention utilizes nanometer-resolution selective laser melting 3D printing technology, using a composite polymer material with a heterogeneous nanocrystalline structure, to ensure the high accuracy of the ear cap's internal structure. The printed internal structure is inspected using a 3D surface inspection algorithm combining fractional Fourier transform and wavelet transform to ensure quality meets design requirements, laying a solid foundation for the subsequent injection molding process. This high-precision manufacturing and inspection technology significantly improves the consistency and reliability of the ear cap product.

[0069] 3. Dynamic Control Combined with Seamless Injection Molding: During the injection molding process, this invention incorporates nonlinear dynamic control of time, temperature, and shear rate, along with an adaptive multidimensional sensing system. This system uses thermal-compression coupled dynamic equations to optimize material flow and distribution in real time, ensuring a tight fit and seamless transition between the various components of the two-color ear cap. These dynamic control technologies ensure that the ear caps maintain excellent structural integrity and consistent appearance after secondary injection molding, eliminating the issues of loose bonding and interface defects common in traditional processes.

[0070] 4. Innovative KT Processing and Surface Treatment: This invention incorporates multi-band laser transfer technology, adaptive photoacoustic laser engraving technology, and nano-scale surface coating technology into the ear cap surface treatment, significantly improving the complexity, fineness, and durability of the ear cap's pattern. Through plasma cleaning and chemical modifier treatment, the ear cap's surface energy is significantly improved, ensuring the adhesion and uniformity of the coating. Combined with these innovative technologies, the ear cap not only possesses a highly personalized and unique appearance, but also enhances antibacterial, anti-fouling, and UV protection.

[0071] 5. Comprehensive Quality Control and Intelligent Packaging: During the final quality inspection of the ear caps, this invention uses optical interferometry technology to perform multi-dimensional tests on dimensional accuracy, wear resistance, color durability, and surface finish, ensuring that each finished product meets strict quality standards. The final intelligent packaging process not only provides product information but also provides anti-counterfeiting features, significantly enhancing product safety and market competitiveness.

[0072] Through the above-mentioned technical means, the present invention solves the problems of weak material bonding, poor surface treatment effect, insufficient personalized design and imperfect quality inspection in the existing two-color ear cap manufacturing process, significantly improves the manufacturing quality, durability and aesthetics of the ear caps, and meets the market demand for high-quality, multifunctional ear caps. BRIEF DESCRIPTION OF THE DRAWINGS

[0073] The accompanying drawings are used to provide a further understanding of the present invention and constitute a part of the specification. Together with the embodiments of the present invention, they are used to explain the present invention and do not constitute a limitation of the present invention. In the accompanying drawings:

[0074] Figure 1 This is a summary of the KT process for double-color ear caps proposed by the present invention;

[0075] Figure 2 This is the flow chart of claim 2 of the KT process for double-color ear caps proposed in the present invention;

[0076] Figure 3 This is the flow chart of claim 5 of the KT process for making two-color ear caps proposed by the present invention. DETAILED DESCRIPTION

[0077] The present invention will now be described in further detail with reference to the accompanying drawings, which are simplified schematic diagrams that illustrate the basic structure of the present invention in a schematic manner.

[0078] refer to Figure 1-3 The KT process for double-color ear caps includes the following steps:

[0079] S1. Provide a mold with an adjustable temperature control system and a dynamic flow channel structure, the mold comprising a first injection cavity and a second injection cavity;

[0080] S2. Use 3D printing technology to manufacture the internal structure of the ear cap. After printing, automatically inspect the internal structure using a 3D surface detection algorithm. Place the qualified internal structure of the ear cap into the first injection cavity of the mold and position it using an automatic alignment system based on quantum particle swarm optimization.

[0081] S3, injecting a plastic material of a first color into a first injection cavity, and forming a first part of the ear cap on the 3D printed internal structure through an injection molding process;

[0082] S4. After the injection molding of the first part is completed, an automatic alignment system based on a multi-dimensional nonlinear dynamic chaos algorithm is used to accurately transfer the partially molded ear cap from the first injection cavity to the second injection cavity to optimize the accuracy of the docking between the first and second parts;

[0083] S5. Injecting a second color of plastic material into a second injection molding cavity to form a second portion of the ear cap through a secondary injection molding process. Optimizing uniform material distribution through thermal-compression coupled dynamic equations to optimize the seamless integration of the second portion with the first portion. After the secondary injection molding is completed, cooling is performed using a multiphase cooling system to optimize the overall structure of the ear cap to prevent deformation or stress concentration during the curing process.

[0084] S6. Multifunctional surface treatment of the two-color ear caps, including antibacterial coating, antifouling coating and UV protection coating, to optimize the durability and hygiene performance of the ear caps;

[0085] S7. Use the KT process to form complex patterns, logos, or textures on the ear cap surface. The depth and quality of the laser engraving are described and optimized using the Kramers-Kronig relationship. After cleaning, check the surface finish.

[0086] S8. Conduct quality inspection on the two-color ear caps after surface treatment, including dimensional accuracy, wear resistance and color durability tests;

[0087] S9. The two-color ear caps that have passed the quality inspection will be packaged and a smart label with product information will be added to the package.

[0088] In this embodiment, S2 specifically includes:

[0089] S21. Use a 3D design tool based on metamaterial properties and multi-scale modeling to design the internal structure of the ear cap. During the design process, a multi-objective Bayesian optimization algorithm combined with shape optimization techniques using fractional calculus was used to adjust key design parameters of the internal structure, including the skeleton thickness T, aperture D, and support position P:

[0090]

[0091] in, is the objective function, is the structural field function, α and β are the weight factors of Bayesian optimization and fractional calculus, is the gradient vector, Ω is the design space;

[0092] S22. Convert the optimized 3D model into a file suitable for nano-resolution 3D printing and import it into a selective laser melting printer. The printing material is a composite polymer with a heterogeneous nanocrystalline structure. The Young's modulus E and density ρ of the material are preprocessed using the nonlinear stress-strain relationship:

[0093]

[0094] Where σ(∈) is stress, ∈ is strain, Γ(∈) is the nonlinear gauge factor function, E0 and ρ0 are the initial Young's modulus and density of the material;

[0095] S23. Before 3D printing, the printing parameters are optimized using a deep generative adversarial network based on a co-evolutionary strategy. The deep generative adversarial network based on the co-evolutionary strategy generates a set of printing parameters, including layer thickness H, printing temperature T, and scanning speed V, through game training between the generative and discriminative networks:

[0096]

[0097] Among them, G(H,T,V) is the objective function, G(z) and D(x) are the generating network and discriminant network respectively, Ω(H,T,V) is the regularization term for printing parameter optimization, λ is the weight parameter, and p data (x) and p z (z) are data distribution and noise distribution respectively;

[0098] S24. Start the 3D printer and print layer by layer according to the printing parameter set generated by the deep adversarial generative network of the collaborative evolutionary strategy. During the printing process, a multimodal adaptive control algorithm is used to monitor and adjust the printing temperature T and material deposition speed V in real time. The temperature control equation is:

[0099]

[0100] Where k(T) is the temperature-dependent thermal conductivity, Q is the internal heat source term, and c p is the specific heat capacity, To control the coefficient, the temperature gradient and heat source terms are adjusted;

[0101] S25. After printing is completed, the internal structure is automatically inspected using a three-dimensional surface inspection algorithm that combines fractional Fourier transform and wavelet transform. During the inspection process, Fourier transform analyzes the multi-scale characteristics of surface roughness, and wavelet transform is used to optimize local details.

[0102] S26. Place the internal structure of the ear cap that has passed the multi-scale surface inspection in the first injection cavity of the mold and position it through an automatic alignment system based on quantum particle swarm optimization. The alignment process adjusts the position through the phase interference effect of the quantum superposition state.

[0103] In this embodiment, S3 specifically includes:

[0104] S31, placing the internal structure of the ear cap optimized in S26 into the first injection cavity of the mold, and using the alignment system to position the internal structure to optimize the quality of subsequent injection molding;

[0105] S32. Selecting a first color plastic material suitable for injection molding, wherein the first color plastic material has a thermosensitive response characteristic and can adjust its viscosity during processing, and heating the material to a specified temperature;

[0106] S33. Start the injection molding machine and inject the heated first color plastic material into the first injection cavity of the mold. During the injection molding process, the nonlinear coupling effect formula integrating time, temperature, and shear rate optimizes the dynamic control of material fluidity and stability by considering the oscillatory response and time decay characteristics of the material during processing:

[0107]

[0108] in, is the time-varying effective viscosity of the material, η0 is the initial viscosity of the material under reference conditions, δ, α, β, λ, γ are the characteristic coefficients of the material, ω is the time-dependent oscillation frequency, T is the current material temperature, T m is the melting point temperature of the material, is the shear rate, n is the rheological index, t is the time, and τ is the time constant of the material, which describes the characteristics of the material viscosity decaying with time;

[0109] S34. After the injection molding is completed, the mold temperature is controlled by the cooling system, and the material is gradually solidified at an appropriate cooling rate to form the first part of the ear cap, thereby optimizing the reduction of stress inside the material during the solidification process;

[0110] S35. After cooling and solidification, use measuring equipment to inspect the size and surface finish of the first molded part.

[0111] In this embodiment, the S5 specifically includes:

[0112] S51. Remove the first part of the ear cap formed in step S3 from the first injection molding cavity and transfer it to the second injection molding cavity of the mold using an automated alignment system. During this process, an alignment system based on a multi-dimensional nonlinear dynamic chaos algorithm is used to optimize the accuracy of the docking between the first part and the second part.

[0113]

[0114] Among them, L i,1 and L i,2 denote the local lengths of the first and second parts at the joint, λ i , γ i is the nonlinear counter-position coefficient, τ i is the time constant, α, β, θ are adjustment parameters, t is the time, and N is the number of sampling points;

[0115] S52, selecting a second color plastic material with high elasticity and wear resistance, and preheating the second color plastic material to a temperature range T2 suitable for injection molding;

[0116] S53, start the injection molding machine, and inject the heated second color plastic material into the second injection cavity of the mold. The rheological behavior of the second color plastic material during the injection molding process is very complex, involving multiple physical phenomena, and the viscosity η fusion It is described by the following multivariable coupling formula:

[0117]

[0118] in, Effective viscosity after fusion ηfusion , T current temperature, Shear rate, φ material interaction parameter, ω vibration frequency, η0 base viscosity, n1 and m1 rheological parameters, β1 is a dimensionless coefficient used to adjust the intensity of the effect of shear rate on viscosity, E a Activation energy of material molecular motion, R gas constant, cosh hyperbolic cosine function, cosh(x) represents the hyperbolic cosine function, which is used to describe the complex nonlinear relationship between viscosity over time, interaction force and vibration frequency, λ time-dependent parameter, α thermal expansion coefficient, T m Material melting point temperature, δ and ζ nonlinear adjustment parameters;

[0119] S54. During the injection molding process, an adaptive multi-dimensional sensing system is used to monitor the temperature and pressure distribution of the second part of the material in real time. The thermal-pressure coupling dynamic equation is used to optimize the uniform distribution of the material and seamlessly integrate it with the first part:

[0120]

[0121] in, represents the multidimensional coupled gradient of temperature and pressure, is the partial derivative of pressure P with respect to temperature T, α3 is the coupling coefficient related to the thermal properties of the material, δ and β are adjustment parameters for controlling the nonlinear response of temperature, T and time t, β2 is the pressure fluctuation coefficient, which is used to adjust the response of pressure with time and vibration frequency ω, ω is the vibration frequency, θ is the time-related adjustment parameter, which controls the coupling effect between vibration frequency and time, τ3 is the time constant, λ3 is the attenuation coefficient, which describes the gradual weakening of the effect of temperature on pressure over time, R is the gas constant, T c is the critical temperature of the material, which serves as a reference temperature to measure the effect of actual temperature on the material behavior. ζ is a temperature-dependent nonlinear adjustment parameter that regulates the effect of temperature on the coupling gradient.

[0122] S55. After the injection molding of the second part is completed, a multi-phase cooling system is used for cooling to optimize the overall structure of the ear cap so as not to cause deformation or stress concentration during the curing process.

[0123] In this embodiment, the S7 specifically includes:

[0124] S71. Pre-treat the surface of the ear cap after double-color injection molding. The pre-treatment includes using plasma cleaning combined with specific chemical modifiers to treat the ear cap surface. The surface energy is increased by generating functional groups. The change in surface energy is described by the Frumkin isotherm adsorption model:

[0125]

[0126] Where θ represents the surface coverage, the adsorption ratio of the modifier on the ear cap surface; K is the adsorption equilibrium constant, C is the concentration of the modifier, and a represents the interaction strength between the adsorbed molecules;

[0127] S72. After surface pretreatment, the first step of the KT process is to form a basic pattern on the ear cap surface using laser transfer technology. During the laser transfer process, the energy absorption and conversion of the material is described by the Wagner model:

[0128]

[0129] Where η represents the overpotential of the material surface under laser action, that is, the electrochemical potential difference in the energy conversion process; R is the gas constant, T is the absolute temperature, n is the number of electron transfers, F is the Faraday constant, j is the current density, and j0 is the exchange current density;

[0130] S73. After the base pattern is transferred, the pattern and text are engraved on the surface of the ear cap using laser engraving technology. The depth and quality of the laser engraving are described and optimized using the Kramers-Kronig relationship:

[0131]

[0132] Where n(ω) represents the refractive index of the material, reflecting the speed of light propagation in the material; k(ω') is the absorption coefficient, describing the material's ability to absorb light; ω and ω' are the frequencies of light;

[0133] S74. After laser engraving is completed, the ear cap surface is cleaned using a multiphase fluid dynamics cleaning model to remove small particles and chemical residues.

[0134] S75. Perform optical inspection on the surface of the ear cap to check the integrity of the pattern and text as well as the surface finish. Use optical interferometry technology, combined with S71-7S4 data, to verify whether the surface quality of the ear cap meets the design requirements.

[0135] Example

[0136] To verify the feasibility of this invention, an internationally renowned headphone manufacturer was conducting production tests on a new generation of high-end wireless headphones at its R&D center in a Shenzhen electronics manufacturing park. The company hoped to overcome the technical challenges encountered in existing ear cap manufacturing processes, such as weak material bonding, poor surface treatment, and insufficient pattern complexity, by using a novel two-color ear cap KT process. This would help the company meet the high standards for appearance and functionality in the high-end market.

[0137] The two-color ear cap KT process of this invention is used to manufacture the ear cap. A mold with an integrated adjustable temperature control system and a dynamic flow channel structure ensures precise control of temperature and material flow during the injection molding process of different materials. The mold is designed to contain two injection cavities, one for two-color injection molding, ensuring that the different colored materials are seamlessly integrated into the ear cap.

[0138] At the outset of the process, the R&D team utilized 3D design tools based on metamaterial properties and multi-scale modeling to optimize the internal structure of the ear cap. During the design process, a multi-objective Bayesian optimization algorithm combined with fractional calculus techniques was used to adjust the thickness, aperture, and support positions of the internal skeleton of the ear cap to ensure stability and comfort when worn. Once the design was complete, the generated 3D model was converted into a file suitable for nano-resolution 3D printing and printed using a selective laser melting printer using a composite polymer material with a heterogeneous nanocrystalline structure. Quality control during the printing process utilized a high-precision 3D surface inspection algorithm to ensure that the printed internal structure met the design requirements.

[0139] Next, the inspected internal structure of the ear cap is placed in the first injection molding cavity at the Shenzhen production base. An automated alignment system ensures precise positioning, eliminating the manual errors that can occur with traditional processes. Subsequently, the first color of plastic material is heated to the specified temperature and injected into the first molding cavity. This injection molding process forms the first part of the ear cap over the 3D-printed internal structure. During this process, the system integrates dynamic control algorithms for time, temperature, and shear rate to optimize material flow and stability, ensuring uniformity and molding accuracy for the first part.

[0140] After the first part is molded and cooled, the ear cap is automatically transferred to the second injection cavity. A second color of rubber material is heated to a suitable injection temperature and injected into the second cavity, forming the second part of the ear cap over the first part through a secondary injection molding process. During the secondary injection molding process, the system uses adaptive multi-dimensional sensors to monitor the material's temperature and pressure distribution in real time. Using thermal-pressure coupled dynamic equations, the system optimizes the uniform distribution of the material, ensuring a seamless integration of the two-color sections of the ear cap.

[0141] After the two-color ear caps are injection molded, their surfaces undergo a multifunctional treatment. First, plasma cleaning removes surface impurities, and the surface is treated with a specific chemical modifier to generate polar functional groups to increase surface energy. Multi-band laser transfer technology is then used to form a base pattern on the ear cap surface, and adaptive photoacoustic laser engraving technology is used to create complex patterns and text. Finally, the surface of the ear caps undergoes a nano-scale coating treatment to further enhance the pattern's wear resistance and UV resistance, and to impart a dynamic optical effect under varying lighting conditions.

[0142] The manufacturer implemented the two-color ear cap KT process of the present invention at its Shenzhen production base, and the ear caps produced demonstrated excellent performance in subsequent product testing and market feedback. Specific data is as follows:

[0143] Table 1: Two-color ear cap KT process test data table

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[0146] Table 2: Comparison of production efficiency and scrap rate

[0147] Test items Traditional crafts Process of the present invention Improvement ratio Production time 100％ 75％ 25% shorter scrap rate 100％ 80％ 20% reduction

[0148] It can be seen that the ear caps manufactured by the two-color ear cap KT process of the present invention show significant advantages in multiple key performances. The bonding strength of the first and second parts of the ear cap under a tensile force of 150N is 50% higher than the industry standard; through optical interferometry measurement technology, the pattern depth deviation on the surface of the ear cap is controlled within ±0.03mm, and the resolution reaches 1400dpi, which is 40% higher than the traditional process; after 500 hours of UV aging and 30,000 friction cycle tests, the surface of the ear cap did not show obvious fading or damage, and the pattern integrity remained above 95%; antibacterial tests showed that the antibacterial rate of the ear cap surface coating reached 99.95%, effectively preventing bacterial growth; in the user experience test, the comfort score of the ear cap averaged 9.7 points out of 10, and it still maintained good elasticity and fit after being worn continuously for 8 hours. In addition, in large-scale production, the production time was shortened by 25% and the scrap rate was reduced by 20%, significantly improving production efficiency and product quality.

[0149] Based on this detailed data, the invented two-color ear cap KT process effectively solves the problems of weak material bonding, poor surface treatment, insufficient personalized design, and incomplete quality control found in traditional processes. The resulting ear caps not only possess extremely high precision and personalized design, but also achieve new heights in durability, functionality, and user experience, significantly enhancing the product's market competitiveness.

[0150] The above description is only a preferred specific embodiment of the present invention, but the scope of protection of the present invention is not limited thereto. Any technician familiar with the technical field, within the technical scope disclosed by the present invention, who makes equivalent replacements or changes based on the technical solution and inventive concept of the present invention, should be covered by the scope of protection of the present invention.

Claims

1. Two-color ear caps with KT technology, It is characterized in that The steps include: S1. Provide a mold with an adjustable temperature control system and a dynamic flow channel structure, the mold comprising a first injection cavity and a second injection cavity; S2. Use 3D printing technology to manufacture the internal structure of the ear cap. After printing, the internal structure is automatically inspected by a three-dimensional surface detection algorithm, and the qualified internal structure of the ear cap is placed in the first injection cavity of the mold and positioned by an automatic alignment system based on quantum particle swarm optimization; S3, injecting a plastic material of a first color into a first injection cavity, and forming a first part of the ear cap on the 3D printed internal structure through an injection molding process; S4. After the injection molding of the first part is completed, the partially molded ear cap is accurately transferred from the first injection molding cavity to the second injection molding cavity by using an automatic alignment system based on a multi-dimensional nonlinear dynamic chaos algorithm to optimize the accuracy of the docking between the first part and the second part; S5, injecting a plastic material of a second color into a second injection molding cavity, forming a second part of the ear cap through a secondary injection molding process, optimizing uniform distribution of the material through a thermal-compression coupling dynamic equation, optimizing seamless combination of the second part and the first part, and after completing the secondary injection molding, performing cooling treatment using a multiphase cooling system, optimizing the overall structure of the ear cap so that no deformation or stress concentration occurs during the curing process; S6. Multifunctional surface treatment of two-color ear caps, including antibacterial coating, antifouling coating and UV protection coating, to optimize the durability and hygiene performance of the ear caps; S7, using KT process to form complex patterns, logos or textures on the surface of the ear cap, the depth and quality of laser engraving are described and optimized by Kramers-Kronig relationship, and the surface finish is checked after cleaning; S8. Conduct quality inspection on the two-color ear caps after surface treatment, including dimensional accuracy, wear resistance and color durability tests; S9. The two-color ear caps that have passed the quality inspection will be packaged and a smart label with product information will be added to the package.

2. The two-color ear cap KT process according to claim 1, It is characterized in that The S2 specifically includes: S21. Use a 3D design tool based on metamaterial properties and multi-scale modeling to design the internal structure of the ear cap. During the design process, the key design parameters of the internal structure, including the skeleton thickness T, aperture D, and support position P, are adjusted by using a multi-objective Bayesian optimization algorithm combined with a shape optimization technique based on fractional calculus: in, is the objective function, is the structural field function, α and β are the weight factors of Bayesian optimization and fractional calculus, is the gradient vector, Ω is the design space; S22. Convert the optimized 3D model into a file suitable for nano-resolution 3D printing and import it into a selective laser melting printer. The printing material is a composite polymer with a heterogeneous nanocrystalline structure. The Young's modulus E and density ρ of the material are preprocessed by the nonlinear stress-strain relationship: Among them, σ(∈) is stress, ∈ is strain, Γ(∈) is the nonlinear strain factor function, E 0 and ρ 0 is the initial Young’s modulus and density of the material; S23. Before 3D printing, the printing parameters are optimized using a deep adversarial generative network based on a co-evolutionary strategy. The deep adversarial generative network based on a co-evolutionary strategy generates a set of printing parameters, including layer thickness H, printing temperature T, and scanning speed V, through game training between the generative and discriminative networks: Among them, G(H,T,V) is the objective function, G(z) and D(x) are the generating network and discriminating network respectively, Ω(H,T,V) is the regularization term for printing parameter optimization, λ is the weight parameter, and p data (x) and p z (z) are data distribution and noise distribution respectively; S24, start the 3D printer, and print layer by layer according to the printing parameter set generated by the deep adversarial generative network of the collaborative evolution strategy. During the printing process, a multi-modal adaptive control algorithm is used to monitor and adjust the printing temperature T and material deposition speed V in real time. The temperature control equation is: Where k(T) is the temperature-dependent thermal conductivity, Q is the internal heat source term, and c p is the specific heat capacity, To control the coefficient, the temperature gradient and heat source terms are adjusted; S25. After printing is completed, the internal structure is automatically detected using a three-dimensional surface detection algorithm that combines fractional Fourier transform and wavelet transform. During the detection process, Fourier transform analyzes the multi-scale characteristics of surface roughness, and wavelet transform is used to optimize local details. S26. Place the internal structure of the ear cap that has passed the multi-scale surface inspection in the first injection cavity of the mold, and position it through an automatic alignment system based on quantum particle swarm optimization. The alignment process adjusts the position through the phase interference effect of the quantum superposition state.

3. The two-color ear cap KT process according to claim 1, Its characteristics are, The S3 specifically includes: S31, placing the internal structure of the ear cap optimized and designed in S26 in the first injection cavity of the mold, and using the alignment system to position the internal structure to optimize the quality of subsequent injection molding; S32, selecting a first color plastic material suitable for injection molding, the first color plastic material having a thermosensitive response characteristic, capable of adjusting its viscosity during processing, and heating the material to a specified temperature; S33, start the injection molding machine, and inject the heated first color plastic material into the first injection cavity of the mold. During the injection molding process, the nonlinear coupling effect formula integrating time, temperature, and shear rate optimizes the dynamic control of material fluidity and stability by considering the oscillation response and time attenuation characteristics of the material during the processing: in, is the time-varying effective viscosity of the material, η 0 is the initial viscosity of the material under reference conditions, δ, α, β, λ, γ are the characteristic coefficients of the material, ω is the time-dependent oscillation frequency, T is the current material temperature, T m is the melting point temperature of the material, is the shear rate, n is the rheological index, t is the time, and τ is the time constant of the material, which describes the characteristics of the material viscosity decaying with time; S34, after the injection molding is completed, the mold temperature is controlled by the cooling system, and the material is gradually solidified at an appropriate cooling rate to form the first part of the ear cap, thereby optimizing the reduction of stress inside the material during the solidification process; S35. After cooling and solidification, use measuring equipment to inspect the size and surface finish of the first molded part.

4. The two-color ear cap KT process according to claim 1, It is characterized in that The S5 specifically includes: S51, removing the first part of the ear cap formed in step S3 from the first injection cavity, and transferring it to the second injection cavity of the mold by using an automated alignment system. In this process, an alignment system based on a multi-dimensional nonlinear dynamic chaos algorithm is used to optimize the accuracy of the docking between the first part and the second part: Among them, L i,1 and L i,2 denote the local lengths of the first and second parts at the joint, λ i , γ i is the nonlinear counter-position coefficient, τ i is the time constant, α, β, θ are adjustment parameters, t is the time, and N is the number of sampling points; S52, select a second color plastic material with high elasticity and wear resistance, and preheat the second color plastic material to a temperature range T suitable for injection molding 2 ; S53, start the injection molding machine, and inject the heated second color plastic material into the second injection cavity of the mold. The rheological behavior of the second color plastic material during the injection molding process is very complex, involving multiple physical phenomena, and the viscosity η fusion It is described by the following multivariable coupling formula: in, Effective viscosity after fusion η fusion , T current temperature, Shear rate, φ material interaction parameter, ω vibration frequency, η 0 Base viscosity, n 1 and m 1 Rheological parameters, β 1 is a dimensionless coefficient used to adjust the effect of shear rate on viscosity, E a Activation energy of material molecular motion, R gas constant, cosh hyperbolic cosine function, cosh(x) represents the hyperbolic cosine function, which is used to describe the complex nonlinear relationship between viscosity over time, interaction force and vibration frequency, λ time-dependent parameter, α thermal expansion coefficient, T m Material melting point temperature, δ and ζ nonlinear adjustment parameters; S54. During the injection molding process, an adaptive multi-dimensional sensing system is used to monitor the temperature and pressure distribution of the second part of the material in real time, and the thermal-pressure coupling dynamic equation is used to optimize the uniform distribution of the material and seamlessly combine it with the first part: in, represents the multidimensional coupled gradient of temperature and pressure, is the partial derivative of pressure P with respect to temperature T, α 3 is the coupling coefficient related to the thermal properties of the material, δ and β are adjustment parameters that control the nonlinear response of temperature, T and time t, β 2 is the pressure fluctuation coefficient, which is used to adjust the response of pressure with time and vibration frequency ω, ω is the vibration frequency, θ is the time-related adjustment parameter, which controls the coupling effect between vibration frequency and time, τ 3 is the time constant, λ 3 is the attenuation coefficient, which describes the gradual weakening of the effect of temperature on pressure over time, R is the gas constant, T c is the critical temperature of the material, which is used as a reference temperature to measure the effect of actual temperature on the material behavior. ζ is a temperature-dependent nonlinear adjustment parameter that regulates the effect of temperature on the coupling gradient. S55. After the injection molding of the second part is completed, a multiphase cooling system is used for cooling to optimize the overall structure of the ear cap so as not to cause deformation or stress concentration during the curing process.

5. The two-color ear cap KT process according to claim 1, It is characterized in that The S7 specifically includes: S71. Pre-treat the surface of the ear cap after double-color injection molding. The pre-treatment includes using plasma cleaning combined with specific chemical modifiers to treat the surface of the ear cap, and increasing the surface energy by generating functional groups. The change in surface energy is described by the Frumkin isotherm adsorption model: Where θ represents the surface coverage, the adsorption ratio of the modifier on the ear cap surface; K is the adsorption equilibrium constant, C is the concentration of the modifier, and a represents the interaction strength between the adsorbed molecules; S72. After the surface pretreatment is completed, the first step of the KT process is to use laser transfer technology to form a basic pattern on the surface of the ear cap. During the laser transfer process, the energy absorption and conversion of the material is described by the Wagner model: Where η represents the overpotential of the material surface under the action of laser, that is, the electrochemical potential difference in the energy conversion process; R is the gas constant, T is the absolute temperature, n is the number of electron transfers, F is the Faraday constant, j is the current density, and j is the current density. 0 is the exchange current density; S73. After the basic pattern is transferred, the pattern and text are engraved on the surface of the ear cap using laser engraving technology. The depth and quality of laser engraving are described and optimized by the Kramers-Kronig relationship: Among them, n(ω) is the refractive index of the material, which reflects the speed of light propagation in the material; k(ω') is the absorption coefficient, which describes the material's ability to absorb light; ω and ω' are the frequencies of light; S74. After laser engraving is completed, the surface of the ear cap is cleaned using a multiphase fluid dynamics cleaning model to remove small particles and chemical residues; S75. Perform optical inspection on the surface of the ear caps to check the integrity of the pattern and text as well as the surface smoothness. Use optical interferometry technology in combination with S71-7S4 data to verify whether the surface quality of the ear caps meets the design requirements.

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