3D Decorative Piece Core Structure for Shape Retention
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Solution Overview
Problem
Existing three-dimensional decorative pieces face limitations in achieving bulkiness and retaining their shape due to uneven heating during high-frequency dielectric heating, leading to thickness constraints and susceptibility to deformation.
Innovation Solution
A three-dimensional decorative piece comprising an upper layer molded body with a metal vapor-deposited layer, a core formed by curing a flowable synthetic resin, and a substrate bonded by fusion, where the core supports the convex portion of the upper layer molded body to enhance shape retention and bulkiness.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Volume of moving object
If the lower layer material is made thicker to achieve bulkiness, then the three-dimensional shape is enhanced, but the heating becomes uneven due to radio wave concentration at edges and corners, making shaping and joining difficult
Solution Approach 1:
The patent divides the decorative piece into multiple layers: an upper layer material with metal vapor-deposited layer, a lower layer material, and a core material filled in cavities. This segmentation allows each layer to serve specific functions - the upper layer provides aesthetic appearance, the lower layer provides structural support, and the core material fills voids to enable uniform heating throughout the thickness, resolving the heating uniformity problem while maintaining bulkiness.
Solution Approach 2:
The patent uses composite materials consisting of thermoplastic synthetic resin with metal vapor-deposited layers and core materials (such as foam or granulated resin). This composite structure enables the decorative piece to achieve both thickness for bulkiness and uniform heating properties, as the core material has different thermal properties that facilitate even heat distribution throughout the structure.
2Volume of moving object
If only the upper layer material is provided without the lower layer material to achieve thickness, then the three-dimensional shape is enhanced, but the thin upper layer material cannot retain its shape and becomes dented or crushed
Solution Approach 1:
The patent applies local quality by placing core material specifically in the cavity portions of the upper layer material, rather than uniformly throughout. This localized reinforcement provides structural support exactly where needed to prevent denting and crushing, while maintaining the overall three-dimensional shape and aesthetic appearance of the decorative piece.
Solution Approach 2:
The patent creates a composite structure combining the thin upper layer material with core material (such as foam or granulated resin). This composite construction provides the necessary strength and shape retention to the thin upper layer, preventing it from being dented or crushed while maintaining the desired thickness and three-dimensional appearance.
3Volume of moving object
If the lower layer material is made thicker to achieve bulkiness, then the three-dimensional shape is enhanced, but the decorative piece is limited to about 2 mm thickness due to heating constraints
Solution Approach 1:
The patent segments the thick decorative piece into multiple manageable layers with cavities filled with core material. This segmentation reduces the continuous material thickness that causes heating problems, allowing each segment to be heated more uniformly while the overall assembly achieves the desired thickness for bulkiness and manufacturability.
Solution Approach 2:
The patent changes the physical parameters of the material structure by introducing core material with different thermal properties into the cavities. This parameter change enables uniform heating throughout the thick structure, making it manufacturable while maintaining the desired thickness for bulkiness.
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
The solution allows for the production of thicker, more bulky decorative pieces that maintain their three-dimensional shape, exceeding conventional thicknesses of 3-10 mm, with enhanced durability against deformation.
Implementation Method 1
an upper layer molded body composed of an upper layer material with a metal vapor-deposited layer and formed into a three-dimensional shape having a convex portion on its front surface side through high-frequency dielectric heating
Implementation Method 2
a core formed by curing a flowable synthetic resin filled in the convex portion of the upper layer molded body
Implementation Method 3
a substrate bonded to a back surface side of the core by fusion
Data Source
AI summary
A three-dimensional decorative piece that is made of a thermoplastic synthetic resin and can retain bulkiness and shape by a core and a method of producing the same. The three-dimensional decorative piece includes an upper layer molded body made of an upper layer material with a metal vapor-deposited layer and having a three-dimensional shape with a convex portion formed on its front surface side through a high-frequency dielectric heating, a core formed by curing a flowable synthetic resin filled in the convex portion of the upper layer molded body, and a substrate bonded a back surface side of the core by fusion.