Fiber Pattern Paper for Molded Surface Features
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Solution Overview
Problem
The high manufacturing costs and time required to prepare multiple molds for forming various patterns in the mold pressing method lead to increased costs of finished products, as each mold is a high-cost, time-consuming product.
Innovation Solution
A pattern forming method using a pattern paper made of fiber materials like carbon fiber, polyketone fiber, aramid, silica, polyester, polyurethane, or nylon, with a reinforced fiber layer on the back, impregnated with a releasing agent and bonded using heat, is applied to an existing mold to form patterns on a target surface.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If multiple metal molds are prepared to form various patterns, then pattern variety is improved, but manufacturing cost and manufacturing time increase
Solution Approach 1:
The patent uses pattern papers as copies or replicas of the actual patterns, adhering them to the mold surface. Instead of creating multiple expensive metal molds for different patterns, the invention creates inexpensive pattern papers that can be applied to a single mold, allowing pattern variety without multiplying the expensive mold infrastructure.
Solution Approach 2:
The invention changes the material parameter of the pattern carrier from rigid metal mold material to flexible pattern paper material. This parameter change allows the pattern to be easily changed by replacing the pattern paper rather than replacing the entire mold, thereby reducing manufacturing cost while maintaining pattern variety.
2Adaptability or versatility
If multiple metal molds are prepared to form various patterns, then pattern variety is improved, but manufacturing time increases
Solution Approach 1:
The pattern papers serve as time-efficient copies that can be quickly prepared and applied to the mold. Creating a pattern paper is much faster than manufacturing a metal mold, so the invention reduces the time investment required to achieve pattern variety by using rapidly producible pattern copies instead of time-consuming metal mold fabrication.
Solution Approach 2:
The pattern papers can be prepared in advance and stored for later use. This preliminary action allows the patterns to be ready before they are needed, eliminating the time-consuming process of creating new molds when patterns are required. The mold itself remains, ready for immediate use with different pattern papers as needed.
3Ease of operation
If pattern paper is impregnated with releasing agent, then ease of separation is improved, but additional processing step is added
Solution Approach 1:
The releasing agent is applied to the pattern paper in advance during the preparation stage, before the actual pattern forming operation. This preliminary action ensures that the separation function is already in place when the pattern paper is adhered to the mold, making the separation process during operation simple and efficient without requiring additional complex mechanisms during the main manufacturing process.
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 pattern formation using fibers instead of metal molds, reducing production costs and time by enabling the creation of various patterns with existing molds, improving durability and ease of separation, and potentially reducing manufacturing time.
Implementation Method 1
impregnating the pattern paper with a releasing agent penetrating into the fiber material
Implementation Method 2
applying heat to the pattern paper and the pattern forming target
Implementation Method 3
bonding the pattern forming layer and the reinforced fiber layer by applying heat
Data Source
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AI summary
Provided is a pattern forming method including: preparing a pattern paper including a fiber where a pattern to be formed is formed; impregnating the pattern paper with a releasing agent; and forming the pattern on a pattern forming target by arranging the pattern paper on a mold including an upper mold and a lower mold, and adhering the pattern paper to the pattern forming target by using the mold. Accordingly, a pattern may be formed by using a fiber instead of a mold of a metal material, and a required pattern may be formed by additionally providing a pattern paper of a fiber material to an existing pattern forming mold.