All-in-one Coating for Light-transmitting Decorated Molding
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Solution Overview
Problem
Conventional methods for fabricating light-transmitting decorated molding articles, such as in-mold decoration (IMD) and out-mold decoration (OMD), face challenges including cumbersome processes, low yield, material wastage, environmental pollution, and difficulty in achieving uniform thickness and alignment, particularly when processing light-transmitting patterns.
Innovation Solution
A method involving the formation of an all-in-one coating comprising protective, ink, and bonding materials on a substrate, followed by blister molding, laser engraving, and the creation of a protective layer using 3D printing or jet printing, which enhances the physical properties and durability of the molded film, allowing for improved alignment and reduced manufacturing costs.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If conventional spraying or printing process is used to form decorations on the surface, then visual effect and appearance variety are improved, but the process becomes cumbersome, yield decreases, and organic solvent gas pollution increases
Solution Approach 1:
The patent combines multiple functions (protective coating, decorative printing, and bonding) into a single all-in-one coating layer. This eliminates the need for separate protective layers and adhesive layers, simplifying the manufacturing process while improving production yield by reducing the number of steps and potential failure points.
Solution Approach 2:
The all-in-one coating layer serves multiple functions simultaneously: it provides protective properties (hardness, scratch resistance), decorative properties (printed patterns), and bonding properties (adhesion to substrate). This multi-functionality resolves the contradiction by eliminating the need for multiple separate layers and processes.
2Reliability
If in-mold decoration with separate protective film and printed pattern layer is used, then surface protection and color durability are improved, but the process becomes time-consuming and costly due to multiple stacking steps
Solution Approach 1:
The patent merges the protective film, printed pattern layer, and bonding layer into a single integrated all-in-one coating layer. This eliminates the time-consuming stacking process while maintaining surface protection and color durability through the multi-functional formulation of the coating material.
Solution Approach 2:
The all-in-one coating layer provides protective, decorative, and bonding functions simultaneously, eliminating the need for multiple separate layers and the time-consuming stacking process associated with conventional in-mold decoration methods.
3Strength
If PMMA substrate is used for in-mold decoration, then hardness and scratch resistance are improved, but the substrate is prone to cracking during hot press process
Solution Approach 1:
The patent changes the material parameters of the coating layer by formulating an all-in-one coating that cures to provide both hardness (for scratch resistance) and flexibility (for crack resistance during hot press). This resolves the contradiction by achieving both properties in a single layer that can accommodate forming processes.
4Manufacturing precision
If multiple separate coating layers are applied for protection and decoration, then surface properties are improved, but material wastage and manufacturing complexity increase
Solution Approach 1:
The patent combines multiple coating functions into a single all-in-one coating layer, eliminating the need for multiple separate coating applications. This reduces material wastage from multiple coating processes while maintaining uniform surface properties through the integrated formulation.
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 approach results in molded films with higher hardness and better protection, enabling efficient laser engraving and reducing production costs by simplifying the manufacturing process and eliminating the need for additional adhesive layers, thereby improving yield and extending the lifespan of the decorated articles.
Implementation Method 1
The coating at least comprises a protective material, an ink material, and a bonding material uniformly mixed together
Implementation Method 2
performing a laser engraving process to form a groove
Data Source
Figure 1
Figure 2A~2B
Figure 3
AI summary
A method of manufacturing a decorated molding article includes: forming an all-in-one coating on a substrate and performing a curing step, thereby forming a composite layer structure with a protective effect, a color effect, and a bonding effect. Compared with the printing layer in the conventional In Mold Label (IML) and InSert molding (INS) that is made by a plurality of anti-impact and bonding processes, the composite layer structure of the embodiment can form a molded film with better physical properties (e.g., higher hardness, better protection effect, etc.) after the blister molding process. Therefore, the molded film of the embodiment can be applied to a laser engraving process to form a variety of light-transmitting decorative molded products. Further, the present disclosure further forms a protective layer locally in the grooves formed after the laser engraving process, so as to protect the texture after the laser engraving process from damage.