Decorated Molding Composite Layer for Adhesive-Free Surface Finishing
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Conventional decoration methods for molding articles, such as spraying and printing, are cumbersome, time-consuming, and environmentally harmful, with issues like low yield, poor uniformity, and high production costs, while existing in-mold decoration techniques face challenges with substrate hardness, cracking, and the need for additional adhesive layers.
Innovation Solution
A decorated molding article with a composite layer structure comprising a substrate, multiple decoration layers, and an optical hardening layer, formed through an all-in-one coating process, which includes protective, ink, and bonding materials, eliminating the need for separate adhesive layers and simplifying manufacturing steps.
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 specific visual effect and appearance variety can be achieved, but the process becomes cumbersome, time-consuming, and environmentally harmful with low yield and poor thickness uniformity
Solution Approach 1:
The patent combines multiple functions (decoration, protection, bonding) into a single integrated coating layer that is applied directly during the molding process. This eliminates the need for separate spraying/printing steps and subsequent adhesive applications, thereby simplifying the manufacturing process while improving production efficiency and eliminating environmental hazards from organic solvents
Solution Approach 2:
The decorative pattern and protective/bonding functions are incorporated into the coating material before the molding process. The coating is applied in advance as part of the shell formation, rather than as a subsequent separate operation. This preliminary integration eliminates multiple processing steps, reduces time consumption, and ensures uniform thickness without requiring post-processing adjustments
2Strength
If substrate includes PC or ABS to reduce cracking, then hardness and scratch resistance improve, but the surface is still susceptible to damage requiring additional protective coating
Solution Approach 1:
The patent merges the protective function with the bonding function by incorporating both protective materials and bonding materials into the same coating layer. This single integrated layer simultaneously protects the substrate surface from damage and provides bonding capability, eliminating the need for separate protective and adhesive layers while maintaining substrate hardness
Solution Approach 2:
The coating layer is designed to perform multiple functions simultaneously: decoration (visual effect), protection (scratch and damage resistance), and bonding (adhesion to decorative films). This multi-functional coating reduces the total number of layers required while enhancing the overall performance of the shell structure
3Strength
If separate adhesive layers are added to bond decorative films, then bonding strength improves, but process complexity and manufacturing steps increase
Solution Approach 1:
The patent combines the bonding function with the protective and decorative coating by incorporating bonding materials into the coating formulation. This integrated coating layer directly bonds decorative films to the shell surface without requiring separate adhesive applications, thereby maintaining strong bonding while significantly reducing process complexity and manufacturing steps
Solution Approach 2:
The coating layer serves as a multi-functional element that simultaneously provides decoration, surface protection, and bonding capability. By integrating these functions into a single layer applied during molding, the patent eliminates the need for separate adhesive layers and reduces the overall number of manufacturing operations required
4Reliability
If multiple separate coating layers are applied for decoration and protection, then functional performance improves, but manufacturing cost and environmental pollution increase
Solution Approach 1:
The patent merges multiple coating functions (decoration, protection, bonding) into a single integrated coating material that is applied as one layer during the molding process. This eliminates the need for multiple separate coating applications, each of which would require organic solvents and curing steps. The single integrated approach maintains all necessary functional performances while eliminating the environmental pollution associated with multiple solvent-based coating processes
Solution Approach 2:
All functional properties (decorative patterns, protective capabilities, bonding agents) are incorporated into the coating material formulation before application. The coating is applied in advance as part of the shell molding process, eliminating the need for subsequent separate coating and curing operations. This preliminary integration reduces environmental pollution by eliminating multiple solvent evaporation steps while maintaining full functional performance
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 method reduces manufacturing costs and environmental pollution by forming a durable, high-hardness, and aesthetically appealing decorative surface with improved yield and reduced process complexity.
Implementation Method 1
a third coating is formed on the second coating by using a coating method or a printing method. Subsequently, a curing step is performed to form the composite layer structure
Data Source
AI summary
Provided is a decorated molding article includes a workpiece and a molded film attached to an outer surface of the workpiece or an inner surface of the workpiece. 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, a plurality of stacked decorative layers of the embodiment not only provide various color effects, but also directly combined with injection molding material to form part products and have both a protection effect and an adhesive effect. Further, the present disclosure can effectively simplify the manufacturing steps of the composite layer structure and reduce the manufacturing cost.