Easy Moldable Paper for 3D In-Mold Decoration
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Solution Overview
Problem
Conventional methods for manufacturing fibrous molded objects face challenges in achieving beautiful decoration due to limitations in shape restrictions and issues with moisture discharge and heat-induced fusion during the drying process, which restrict the application of decorating methods like insert molding and nonwoven fabrics.
Innovation Solution
A method involving the use of easy moldable paper with microcreases, pre-set water content, and integrated pictorial patterns, which is inserted into a mold, allowing for accurate water vapor removal and integration with the fibrous molded object, preventing color migration and fainting, and enabling three-dimensional decoration without lamination steps.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Shape
If a plastic sheet is used for in-mold decorating, then beautiful pictorial patterns can be formed on three-dimensional surfaces, but moisture discharge is blocked and the process becomes too complex for fibrous molded objects
Solution Approach 1:
The patent uses a nonwoven fabric with high water vapor permeability instead of a plastic sheet. The nonwoven fabric's porous structure allows moisture to pass through during the drying step while still providing the decorative function, thus resolving the contradiction between achieving three-dimensional surface decoration and maintaining moisture discharge capability.
Solution Approach 2:
The nonwoven fabric is used as a disposable decorative element that is integrated into the molded object during the molding process. After serving its decorative purpose, it becomes part of the final product structure, eliminating the need for separate moisture discharge mechanisms and simplifying the overall process.
2Object-generated harmful factors
If a nonwoven fabric is used for decorating, then water vapor permeability is improved, but the fabric may fuse due to high temperature and long heating time
Solution Approach 1:
The patent optimizes the drying process parameters including temperature, time, and gap distance (0.02 to 0.50 mm) to achieve effective moisture discharge while preventing nonwoven fabric fusion. The specific gap range and controlled heating conditions allow water vapor to escape before the fabric reaches fusion temperature.
Solution Approach 2:
The drying process is designed to remove moisture to a sufficient degree without applying excessive heat or time that would cause fabric fusion. The partial drying approach achieves the necessary moisture discharge while maintaining fabric integrity through controlled processing conditions.
3Ease of manufacture
If screen printing is used for decoration, then the fibrous molded object can be decorated, but the object must have a flat shape which restricts application range
Solution Approach 1:
The nonwoven fabric is prepared and positioned in the mold before the fibrous material is injected. This preliminary placement allows the fabric to conform to three-dimensional surfaces during the molding process, enabling decoration on complex shapes rather than just flat surfaces.
Solution Approach 2:
The decorative nonwoven fabric is merged with the fibrous molded object during the injection molding process. The fabric becomes an integral part of the final product, combining the structural formation of injection molding with the decorative function of the fabric pattern.
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
This method allows for beautifully decorated fibrous molded objects with enhanced water vapor permeability, preventing color issues and maintaining the integrity of the pictorial patterns, while ensuring the object is wholly made of fibrous material for better tactile feel and recyclability.
Implementation Method 1
filling a cavity of the heated mold with a mixture as a molding material, the mixture being obtained by adding a polymer binding material and water to a main fibrous material and kneading them; forming a gap of 0.02 to 0.50 mm between parting faces of the mold, and discharging and removing water vapor generated in the cavity through the gap to dry and solidify the molding material
Implementation Method 2
adding a polymer binding material and water to a main fibrous material and kneading them; dry and solidify the molding material
Data Source
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AI summary
An in-mold decorated fibrous molded object is provided, which is capable of being beautifully decorated, and a method for manufacturing the same. A method for manufacturing an in-mold decorated fibrous molded object includes the steps of forming a pictorial pattern 2 on an easy moldable paper 1, the easy moldable paper 1 having microcreases formed over the entire surface thereof so that the easy moldable paper has a reduced apparent dimension; inserting the easy moldable paper 1 into a mold 3; clamping the mold; filling a cavity 4 of the heated mold 3 with a mixture as a molding material 5, the mixture being obtained by adding a polymer binding material and water to a main fibrous material and kneading them; forming a gap of 0.02 to 0.50 mm between parting faces of the mold 3, and discharging and removing water vapor generated in the cavity 4 through the gap to dry and solidify the molding material 5; and opening the mold to obtain a fibrous molded object 6 having a surface integrally molded with the easy moldable paper 1.