Cork Composite Injection Molding Bonding
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Solution Overview
Problem
Existing methods for incorporating cork into moulded components face challenges such as peeling of the cork layer and inability to provide the desired appearance and structural stability, limiting its application in shaped products.
Innovation Solution
A method involving placing a cork sheet in an injection mould, injecting thermoplastic resin between the cork and mould, and removing the moulded component, which combines the appearance and mechanical strength of cork with structural stability, using a thermoplastic resin and agglomerated pressed cork tissue in a sandwich configuration.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If cork sheet material is laminated onto resin layer through thermal pressing or adhesive, then cork appearance and feel are achieved, but the cork layer may peel off
Solution Approach 1:
The patent merges the cork sheet material directly with the thermoplastic resin through co-injection molding, creating a monolithic integrated structure where cork and resin are bonded at molecular level during the molding process, eliminating the peeling issue of laminated structures
Solution Approach 2:
The patent creates a composite material system combining natural cork sheet material with thermoplastic resin in a single molded component, where the two materials are chemically and mechanically integrated through the injection molding process, providing both cork's aesthetic properties and resin's structural integrity
2Strength
If cork is used alone for moulded components, then cork appearance and feel are achieved, but structural stability and shape complexity are limited
Solution Approach 1:
The patent employs composite materials combining cork sheet with thermoplastic resin, where the resin provides structural stability and enables complex shapes while the cork layer maintains the desired appearance and tactile properties
Solution Approach 2:
The patent applies local quality by using cork sheet material specifically for the visible and tactile surface areas requiring aesthetic properties, while the thermoplastic resin forms the structural core and hidden portions, allowing each material to be used where it provides maximum benefit
3Object-affected harmful factors
If cork is used in public areas, then aesthetic appearance is achieved, but resistance to vandalism and wear is insufficient
Solution Approach 1:
The patent creates a composite structure where the thermoplastic resin provides vandal-resistant structural support and wear protection, while the cork sheet material maintains the aesthetic appearance, with both materials integrated to work together as a unified surface
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 cork-based composite material provides a durable, vandalism-safe, and fire-resistant surface that maintains the appearance and feel of cork, suitable for public areas and other applications, while ensuring structural integrity and protection against wear.
Implementation Method 1
injecting a thermoplastic resin into a space formed between the cork sheet material and the mould
Data Source
Figure 1~2
AI summary
The invention relates to a new composite material comprising a cork layer (11) and a layer of thermoplastic resin (12) injection moulded onto one side of the cork layer (11). The composite material is suitable for moulded components.