Decorated Sheet Insert Molding with ABS Resin
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Solution Overview
Problem
Decorated sheets used in insert molding for automotive and building interiors face issues with adhesive properties, folding processability, and design damage due to the generation of hazardous gases when vinyl chloride-based materials burn, leading to environmental concerns and unsatisfactory performance.
Innovation Solution
A decorated sheet comprising a base sheet of ABS resin with 10-33% butadiene content, a print layer, and a surface resin layer of 50-150 μm thickness, which enhances rigidity, hardness, and moldability while preventing rubber odor and ink flow, thereby improving insert molding properties and design retention.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If vinyl chloride sheets or vinyl chloride-vinyl acetate copolymer sheets are used as base sheet, then processing aptitude, printing aptitude, and embossing aptitude are excellent and cost is low, but hazardous gases such as chlorine gas are generated during burning causing environmental pollution and incinerator damage
Solution Approach 1:
The patent changes the chemical composition parameters of the base sheet from vinyl chloride-based materials to polyolefin-based materials (specifically polyethylene or polypropylene). This parameter change eliminates the generation of hazardous gases like chlorine during burning while maintaining the necessary processing, printing, and embossing aptitudes required for decorated sheet production
Solution Approach 2:
The patent uses composite material structures where the base sheet is made of polyolefin resin combined with specific adhesive layers and print layers. This composite approach allows the base material to be environmentally safe (non-vinyl chloride) while the layered structure maintains overall processing performance through careful selection of compatible materials in each layer
2Object-generated harmful factors
If polyolefin base resin is used for base sheet, then environmental pollution is reduced, but adhesive property with adherend and folding processability are insufficient
Solution Approach 1:
The patent segments the decorated sheet into multiple functional layers: a polyolefin-based base sheet layer, an adhesive layer, and a print layer. This segmentation allows each layer to perform its specific function optimally - the base sheet provides environmental safety and structural support, while the adhesive layer specifically addresses the adhesive property deficiency of polyolefin materials
Solution Approach 2:
The patent introduces an adhesive layer as an intermediary between the polyolefin base sheet and the adherend (substrate). This adhesive layer acts as a mediator that compensates for the poor adhesive properties of polyolefin resin, enabling reliable bonding without compromising the environmental benefits of using non-vinyl chloride base material
3Shape
If decorated sheet is used for insert molding, then design property is enhanced, but heat from molten resin causes ink in print layer to flow out damaging the design
Solution Approach 1:
The patent modifies the thermal parameters of the decorated sheet by selecting base sheet materials (polyethylene or polypropylene) and configuring layer structures with specific thicknesses. These parameter changes adjust the heat resistance characteristics to allow the sheet to withstand insert molding temperatures without causing ink flow, thereby maintaining manufacturing precision during the molding process
Solution Approach 2:
The patent employs a composite layered structure where the base sheet, adhesive layer, and print layer are carefully selected and combined. This composite structure provides thermal stability during insert molding, protecting the print layer from excessive heat exposure that would cause ink flow, while still allowing the design to be successfully transferred to the molded part
4Strength
If ABS resin with high butadiene content is used for base sheet, then impact resistance is improved, but rubber odor is generated during insert molding at 200°C or higher
Solution Approach 1:
The patent precisely controls the butadiene content parameter in the ABS resin to fall within the range of 10-33% by weight. This parameter optimization maintains sufficient impact resistance for automotive interior applications while preventing the generation of rubber odor during insert molding, as higher butadiene content would cause odor at molding temperatures
Data Source
AI summary
Provided is a decorated sheet for insert molding in which at least a base sheet, a print layer and a surface resin layer are laminated, wherein the above base sheet comprises an ABS resin having a butadiene content of 10 to 33% by weight based on the total component, and the surface resin layer has a thickness of 50 to 150 μm. Capable of being provided is a novel decorated sheet which does not generate harmful gases such as a chlorine gas and the like in burning and therefore does not bring about problems such as environmental pollution and the like and which is excellent in a so-called vacuum molding property and can suitably be used for various interior decorations of automobiles and the like.