Decorating Sheet Maintaining 3D Pattern During Thermoforming
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Solution Overview
Problem
Existing methods for creating three-dimensional patterns on decorated molded products are limited in their ability to achieve a visually three-dimensional sensation, particularly in forming patterns on both the surface and inner sides of molded products, and are hindered by issues such as pattern flattening during vacuum forming, limited ink transfer, and the need for expensive mold changes.
Innovation Solution
A decorating sheet with a transparent resin substrate and a glossy layer, where the front surface is divided into high-gloss and low-gloss portions with varying thicknesses, and a backing sheet for improved adhesion, allowing for a three-dimensional pattern to be maintained through thermoforming and injection molding without flattening, using a laminate of crystalline and non-crystalline resins with specific melting and softening points.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If a thermoplastic resin sheet is used for the substrate sheet of a decorating sheet, then the decorating sheet can be preformed in the vacuum forming step, but the three-dimensional pattern embossed on the decorating sheet is flattened due to the heat used to preform the decorating sheet
Solution Approach 1:
The patent applies composite materials by combining a thermosetting resin substrate sheet with a thermoplastic resin hollow spherical filler. The thermosetting resin provides heat resistance to prevent pattern flattening during vacuum forming, while the thermoplastic filler provides the necessary formability. This composite structure resolves the contradiction between vacuum forming capability and pattern shape retention.
Solution Approach 2:
The patent changes the thermal parameters of the substrate sheet by using a thermosetting resin that undergoes curing at elevated temperatures. The substrate sheet is heated to cure the thermosetting resin, which transforms its properties from formable to heat-resistant, thereby maintaining pattern integrity during subsequent vacuum forming operations.
2Shape
If the decorating sheet is preformed by vacuum forming before injection molding, then the sheet can fit the molded product shape, but the embossed three-dimensional pattern becomes flattened
Solution Approach 1:
The composite structure of thermosetting resin substrate with thermoplastic hollow spherical filler enables the sheet to conform to the molded product shape through vacuum forming while maintaining embossed pattern integrity. The thermosetting resin matrix provides structural support that prevents pattern flattening even when the sheet is formed to match the product geometry.
3Manufacturing precision
If a transparent resin substrate sheet with varying thickness is used to create visual three-dimensional effect, then the pattern gives three-dimensional sensation, but the sheet becomes difficult to form without flattening
Solution Approach 1:
The patent changes the thermal parameters by using a thermosetting resin that can be cured at elevated temperatures. This allows the sheet to be formed at temperatures where the resin is more pliable, and then cured in its final shape to lock in both the formability and the visual three-dimensional effect created by varying thickness.
Solution Approach 2:
The patent utilizes phase transitions of the thermosetting resin through curing. The resin transitions from a moldable state at lower temperatures to a rigid, heat-resistant state after curing at elevated temperatures. This phase transition enables the sheet to be formed without flattening while maintaining the visual three-dimensional effect.
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 provides a decorating sheet that maintains a visually three-dimensional pattern on both the surface and inner sides of molded products, enhancing design complexity and adhesion while avoiding the need for expensive mold changes and pattern flattening, ensuring the pattern remains intact after thermoforming and injection molding.
Implementation Method 1
a laminate of a transparent resin substrate sheet and a glossy layer is heated and embossed
Implementation Method 2
the decorating sheet is softened by heating and is vacuum-formed into the desired shape
Implementation Method 3
a resin is poured into this injection mold and is then hardened, thereby molding the resin into a resin molded product
Data Source
AI summary
A decorating sheet comprises a transparent resin substrate sheet 1 and a glossy layer 2 laminated to the back surface of the transparent resin substrate sheet 1, and the front surface of the transparent resin substrate sheet 1 is divided into high-gloss portions H and low-gloss portions L. The transparent resin substrate sheet 1 is thick at the high-gloss portions and thin at the low-gloss portions, and, owing to these portions, the decorating sheet can provide a pattern that is visually sensed as if it were a three-dimensional pattern. This transparent resin substrate sheet 1 is composed of two layers, a crystalline resin layer 11 and a non-crystalline resin layer 12. A decorated molded product Pd can be obtained by laminating this decorating sheet to a resin molded product 5.