Ceramic-Resin Molding Mold for Laser-Formed Textures
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Solution Overview
Problem
Existing resin molding processes struggle to create high-finish synthetic resin products with embossed patterns and textures, such as leather, skin, wood, and geometric designs, while also addressing issues like background reflection and surface gloss, often requiring additional painting to conceal defects.
Innovation Solution
A resin molding mold with a heat-resistant composite resin layer containing ceramic powder particles, allowing for precise formation of embossed patterns and textures through laser processing, which adsorbs gas and maintains product quality, and a system using a 3D scanner and laser processing machine to create complex surface designs.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If a gloss reduction process is performed by roughening the molding surface by pear skin texture through etching or sandblast processes, then the surface finish is improved, but the manufacturing complexity and time increase
Solution Approach 1:
The mold surface is pre-treated with a resin layer containing ceramic powder particles before the actual molding process. This preliminary preparation allows gas to be adsorbed during molding, preventing defects without requiring additional post-processing steps like etching or sandblasting.
Solution Approach 2:
Instead of permanently modifying the mold surface through complex etching or sandblast processes, the invention uses a consumable resin layer that can be easily applied and removed. This layer serves its purpose during molding and can be discarded without affecting the base mold.
2Manufacturing precision
If additional painting is applied to conceal defective appearance, then the product aesthetic quality is improved, but the manufacturing time and process complexity increase
Solution Approach 1:
The resin layer with ceramic powder particles preemptively prevents gas-related defects during the molding process itself. By adsorbing gas before it can cause visible defects, the need for subsequent painting or cosmetic repairs is eliminated.
Solution Approach 2:
The resin layer automatically performs the function of preventing surface defects through its gas-adsorbing properties. The ceramic powder particles self-organize to create pathways for gas escape and adsorption, eliminating the need for separate corrective operations.
3Reliability
If the resin layer thickness is increased to improve gas adsorption, then the product quality is improved, but the surface processing precision becomes more difficult to control
Solution Approach 1:
The invention optimizes the resin layer thickness to a specific range (50-800 μm) that balances gas adsorption capability with surface processing precision. This parameter optimization ensures sufficient ceramic powder particles are present for gas adsorption while maintaining controllability during laser surface processing.
Solution Approach 2:
The resin layer is formulated as a composite material containing synthetic resin and ceramic powder particles in specific proportions. This composite structure provides both the gas adsorption functionality (through ceramic particles) and the processability (through resin matrix), achieving a balance between quality and precision.
4Adaptability or versatility
If laser processing is used to form embossed patterns on the resin layer, then the design flexibility is improved, but the manufacturing complexity increases
Solution Approach 1:
Traditional mechanical methods for creating embossed patterns (such as physical mask alignment and chemical etching) are replaced with laser processing. The laser directly writes the desired patterns onto the resin layer, eliminating complex mechanical positioning and multiple processing steps.
Solution Approach 2:
The resin layer serves as a temporary carrier for the embossed pattern design. After the laser forms the desired patterns on the resin layer, the layer is transferred to the mold and cured. The resin layer is then discarded, leaving only the permanent embossed pattern on the final product.
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 enables the stable production of high-quality resin products with desired surface shapes and textures, reducing the need for additional painting and enhancing design flexibility.
Implementation Method 1
gas generated in a resin molding state is effectively adsorbed by the ceramic powder particle exposed on the mold surface side
Implementation Method 2
the recesses and projections are formed on the resin layer by excavating a portion of the resin layer... achieved by adjusting an output magnitude of a laser processing machine LP
Data Source
AI summary
To provide a resin molded product having a desired surface shape, a resin molding mold which can manufacture the resin molded product and a method of manufacturing the same, and a resin molding mold manufacturing system to achieve manufacturing of the resin molding mold, a resin molding mold according to the present invention includes a molding mold main body and a resin layer exposedly formed on a mold surface side of the molding mold main body, made of a heat-resistant complex material containing a synthetic resin, and a ceramic powder particle, and having a thickness of 50 to 800 μm. The resin molding mold according to the present invention includes the molding mold main body and the resin layer exposedly formed on the mold surface side of the molding mold main body and made of the heat-resistant composite materials including a synthetic resin, and the ceramic powder particle, and recesses and projections are formed on the resin layer by excavating a portion of the resin layer.