3D Decorative Strip Production via High-Frequency Dielectric Heating
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Solution Overview
Problem
The production of long strips of three-dimensional decorative pieces of thermoplastic synthetic resin is challenging due to limitations in die width and length, making it difficult to create long decorative tapes like striped woven gold wires, which are time-consuming to process and have decreased in availability due to market limitations.
Innovation Solution
A method and apparatus that involve feeding a decorative strip material with three layers, preheating, shaping using high-frequency dielectric heating between rotating electrode rolls, and cooling to produce a long strip of three-dimensional decorative piece, allowing for continuous production and shaping of thermoplastic synthetic resin strips.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Length of moving object
If conventional high-frequency dielectric heating with fixed dies is used to produce three-dimensional decorative pieces, then the shaping and fusion-bonding of the decorative strip material is achieved, but the length of the producible strip is limited by the die dimensions
Solution Approach 1:
The conventional fixed die is segmented into multiple electrode rolls (upper electrode roll die and lower electrode roll die) that can be arranged in sequence along the feeding direction. This allows the decorative strip material to be processed in continuous segments, enabling production of long strips beyond the limitations of a single die size.
Solution Approach 2:
The invention transitions from a two-dimensional fixed die configuration to a three-dimensional arrangement where electrode rolls are positioned at different heights and can be stacked vertically. This dimensional change allows multiple processing zones to be arranged both horizontally and vertically, significantly increasing the productive length for long strip production.
2Productivity
If conventional weaving methods are used to produce long decorative tapes like striped woven gold wires, then long decorative tapes can be produced, but the processing time is extremely long and manufacturer availability has decreased
Solution Approach 1:
The conventional batch processing method is replaced with a continuous processing system where the decorative strip material is fed continuously through multiple electrode rolls. The synchronous rotation of upper and lower electrode rolls enables uninterrupted shaping and fusion-bonding, dramatically increasing production efficiency and reducing processing time compared to traditional weaving methods.
Solution Approach 2:
The invention replaces the mechanical weaving process with high-frequency dielectric heating and shaping. Instead of mechanically interlacing threads to create decorative patterns, the system uses electromagnetic energy to soften, shape, and fuse thermoplastic synthetic resin material, achieving similar aesthetic effects with vastly improved production speed and efficiency.
3Ease of manufacture
If the protective retention layer is made removable after shaping, then the three-dimensional decorative piece can be separated for application, but the layer structure must be designed to allow controlled separation
Solution Approach 1:
The protective retention layer is designed with predetermined separation characteristics that allow easy removal after the shaping process. The layer structure is pre-configured with appropriate adhesive properties and thickness to maintain integrity during processing but enable controlled separation afterward, facilitating application to various substrates without requiring complex removal mechanisms.
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
Enables the efficient production of long strips of three-dimensional decorative pieces with various patterns, overcoming the limitations of die width and length, and addressing the scarcity of long woven decorative tapes by continuously shaping and cooling the thermoplastic synthetic resin.
Implementation Method 1
a step of preheating the decorative strip material to soften the strip material with heat
Implementation Method 2
a step of shaping the decorative strip material into a strip of three-dimensional decorative piece by continuously oscillating a high-frequency in between a rotatable upper electrode roll die and a rotatable lower electrode roll die and applying high-frequency dielectric heat to the decorative strip material between the upper and lower electrode roll dies
Implementation Method 3
a step of cooling the shaped strip of three-dimensional decorative piece
Data Source
AI summary
A method and an apparatus for producing a long strip of three-dimensional decorative piece made of thermoplastic synthetic resin. The method for producing the strip of three-dimensional decorative piece made of thermoplastic synthetic resin according to the present invention comprises the steps of feeding a decorative strip material, preheating the decorative strip material and softening the decorative strip material with heat, shaping the decorative strip material into a strip of three-dimensional decorative piece by continuously oscillating a high-frequency in between a rotatable upper electrode roll die and a rotatable lower electrode roll die and applying high-frequency dielectric heat to the decorative strip material between the upper and lower electrode roll dies, cooling the shaped strip of three-dimensional decorative piece, and winding up the cooled strip of three-dimensional decorative piece.