Embossed Decorative Elements via Thermoplastic Injection Moulding
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Solution Overview
Problem
Existing methods for creating embossed decorative elements on physical supports, such as labels, require complex equipment, skilled operators, and are time-consuming and costly, with thermoplastic material choices often limited by the support material type.
Innovation Solution
A method involving a simplified process using a female mould with a cavity to inject and extrude thermoplastic polymer material onto the support, facilitated by a 3D-printed high-temperature resin mould and a gear extruder, allowing for rapid formation of embossed elements on various materials without complex equipment.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If micro-injection or over-injection of thermoplastic material is used to form embossed elements, then embossed decorative elements can be obtained on physical supports, but the equipment becomes particularly complex and requires skilled operators
Solution Approach 1:
The patent extracts the essential function of forming embossed elements from complex micro-injection equipment and implements it through a simple female mould with cavity that receives molten thermoplastic material. The complex injection apparatus is replaced by a basic mould structure that can be easily positioned and removed, eliminating the need for specialized equipment while maintaining embossed element formation capability.
Solution Approach 2:
The patent employs a simple, inexpensive female mould that can be quickly positioned, used for injection, and removed. The mould structure is basic enough to be considered a disposable or single-use component that does not require complex mechanisms, skilled operation, or expensive equipment, thereby resolving the contradiction between manufacturing precision and device complexity.
2Manufacturing precision
If complex injection moulding processes are used to form embossed elements, then decorative elements can be created, but the production time and costs increase significantly
Solution Approach 1:
The patent applies preliminary action by pre-forming a simple female mould with the desired cavity shape before the injection process. This pre-prepared mould structure allows for rapid positioning and immediate injection without requiring complex real-time forming operations, thereby reducing production time while maintaining the definition of embossed elements through the pre-designed cavity geometry.
Solution Approach 2:
The patent replaces complex mechanical injection moulding systems with a simplified approach where a pre-formed female mould receives molten thermoplastic material. The complex mechanical moulding mechanisms are substituted by a basic receptacle structure that relies on the fluid state of the thermoplastic material to fill the cavity, significantly reducing production time and equipment complexity.
3Manufacturing precision
If traditional injection moulding methods are used, then embossed elements can be formed, but the choice of thermoplastic polymer material is limited by the support material type
Solution Approach 1:
The patent achieves universality by designing a female mould with a cavity that can accommodate molten thermoplastic material regardless of the underlying support material type. The mould structure serves multiple functions: containing the molten material, defining the embossed element shape, and facilitating easy removal. This universal mould design allows the same basic structure to work with various support materials and thermoplastic polymer choices, eliminating material compatibility restrictions.
Solution Approach 2:
The female mould with cavity acts as an intermediary between the molten thermoplastic material and the support material. This intermediary structure mediates the interaction by providing a standardized interface that receives the thermoplastic material and transfers the embossed shape, thereby decoupling the material selection from the support material type and enabling greater versatility in material choices.
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 creation of high-definition embossed elements on diverse materials with reduced production time and costs, using minimal thermoplastic material and maintaining a seal during injection, regardless of the support material.
Implementation Method 1
melting and extrusion of a thermoplastic polymer material and injection of the molten thermoplastic polymer material inside the cavity C
Implementation Method 2
cooling and hardening of the injected thermoplastic polymer material in order to obtain the embossed decorative element
Data Source
Figure 1~3
AI summary
Method for realizing embossed decorative elements on physical supports, comprising a step i) of providing a physical support (B) with a visible surface (B1); a step ii) of arranging on the support (B) a mould (S) provided with a cavity (C) having an opening (A) formed on a surface (S1) of the mould (S), said surface (S1) being placed in contact with the visible surface (B1) of the physical support (B) so that the visible surface (B1) closes the cavity (C) of the mould (S), a step iii) involving melting and extrusion of a thermoplastic polymer material and injection of the melted thermoplastic polymer material inside the cavity (C), the injected thermoplastic polymer material being designed to come into contact with the visible surface (B1) of the physical support (B), a step iv) of cooling and hardening of the injected thermoplastic polymer material so as to obtain the embossed decorative element, and a step v) of removal of the mould (S) from the physical support (B).