In-Mold Decorative Film Stretching Mold with Core Ejection
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Solution Overview
Problem
Current in-mold decoration technologies face limitations in achieving high stretching depths and efficient processing for in-mold decorative films, with existing methods either providing insufficient height difference or requiring complex and inefficient pretreatment processes.
Innovation Solution
A product mold design incorporating high-temperature and high-pressure air heating, a core ejection mechanism, and sequential vacuum adsorption within a closed mold to achieve high-stretching of in-mold decorative films, utilizing a trinity of film heating, mechanical stretching, and vacuum adsorption for precise control and efficient processing.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If vacuum adsorption is used to stretch the film in the mold, then the stretching depth can be increased, but the process complexity increases and production efficiency decreases
Solution Approach 1:
The patent combines film heating, mechanical stretching by core ejection, and vacuum adsorption into a single integrated mold system. The heating channel is built into the core block, and the core ejection mechanism works in conjunction with vacuum adsorption, eliminating the need for separate external heating devices and complex pretreatment processes.
Solution Approach 2:
The patent uses pneumatic systems for both heating (hot air circulation through the core block) and stretching (vacuum adsorption). The heating channel circulates hot air to heat the film, while the vacuum system provides adsorption force for stretching, replacing complex mechanical pretreatment systems.
2Temperature
If external heating is used before molding, then the film can be stretched, but energy consumption increases and thermal energy is lost
Solution Approach 1:
The heating function is merged into the mold's core block through integrated heating channels. The hot air heater is positioned within the mold cavity, allowing direct heating of the film during the molding process itself, eliminating the need for separate external heating equipment and reducing thermal energy loss.
Solution Approach 2:
The mold performs its own heating function through the built-in heating channels in the core block. The system heats the film autonomously during the molding process without requiring external heating equipment, making the mold self-sufficient for both heating and shaping operations.
3Manufacturing precision
If multiple pretreatment steps are used for film stretching, then larger stretching can be achieved, but production efficiency decreases
Solution Approach 1:
Multiple functions (heating, stretching, shaping) are merged into a single integrated mold system. The core block contains both heating channels and ejection mechanisms that work simultaneously with vacuum adsorption, allowing all stretching operations to be completed in one molding cycle without separate pretreatment steps.
Solution Approach 2:
The molding process continues uninterrupted with heating, stretching, and shaping occurring in sequence within the same mold cycle. The core ejection mechanism provides continuous mechanical stretching while vacuum adsorption maintains continuous holding force, eliminating downtime between pretreatment and molding operations.
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 enables high-stretching products with a 20 mm height drop and 7° angle, enhancing design freedom, reducing energy consumption, and improving production efficiency and product quality by maintaining thermal energy and minimizing process complexity and human intervention.
Implementation Method 1
the film is heated by high-temperature and high-pressure air
Implementation Method 2
the film is sequentially stretched by vacuum adsorption at the synchronous cavity side
Data Source
AI summary
A mold for high stretching of an in-mold decorative film, comprising an upper base, a stationary mold, a film pressing frame, a movable mold and a lower base sequentially arranged from top to bottom. The film pressing frame can move up and down; a film to be stretched is placed between the film pressing frame and the stationary mold; a cavity block is fixed in the stationary mold, the lower surface of the cavity block is provided with air holes, and the upper surface is provided with a vacuum air pumping cavity communicated with the air holes; a core block is fixed in the movable mold, and a core ejection movable block is arranged in the core block; the core ejection movable block and the movable mold are provided with a heated air inlet channel and an air outlet channel which are communicated with the outside.