Flat Plate Rubber Pressing Member for Large Area Hot Stamping
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Solution Overview
Problem
Conventional hot stamping methods face challenges in achieving uniform decorative layers on large vehicle grilles with spaced-apart surface sections due to positional deviations and low dimensional accuracy, leading to transfer defects and increased manufacturing costs.
Innovation Solution
A method involving a heated pressing member with a flat plate-shaped rubber piece of specific hardness and thickness, which is curved to fit the surface shape, allowing for uniform contact and reliable transfer of decorative layers even with positional deviations, using controlled pressure to ensure consistent decoration across large areas.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Area of stationary object
If conventional hot stamping with recessed rubber pieces is used, then small components can be decorated, but large components (exceeding 400 mm) cannot be decorated uniformly due to positional deviations
Solution Approach 1:
The patent changes the physical parameters of the pressing member by using a flat plate-shaped rubber piece with specific hardness (30-80 degrees) and thickness (3-10 mm) instead of conventional recessed rubber pieces. This parameter change allows the pressing member to accommodate positional deviations while maintaining uniform contact pressure across large decorated areas exceeding 400 mm.
Solution Approach 2:
The patent employs a flat plate-shaped rubber piece that can elastically deform to conform to the transfer sheet and accommodate positional deviations. The rubber material's flexibility allows it to maintain uniform contact across large areas despite variations in the positions of surface sections to be decorated, solving the dimensional accuracy problem in large component decoration.
2Manufacturing precision
If multiple hot stamping processes are performed with segmented stamping plate, then positional deviations can be corrected, but manufacturing costs increase
Solution Approach 1:
The patent creates a universal pressing member (flat plate-shaped rubber piece) that can handle all surface sections to be decorated on large components in a single hot stamping process. This multi-functional pressing member eliminates the need for segmented stamping plates and multiple processing steps, thereby maintaining position alignment while improving manufacturing efficiency and reducing costs.
Solution Approach 2:
The patent merges multiple decoration operations into a single hot stamping process by using a unified flat plate-shaped rubber piece that contacts all surface sections simultaneously. This consolidation of operations eliminates the need for multiple separate stamping processes, reducing both time and cost while maintaining manufacturing precision.
3Stress or pressure
If rubber piece is shaped to fit each surface section, then contact uniformity is achieved for that section, but misalignment occurs between sections
Solution Approach 1:
The patent uses a flat plate-shaped rubber piece that leverages the material's elastic properties to simultaneously achieve uniform contact pressure across all surface sections and accommodate positional misalignments. The rubber's flexibility allows it to deform and conform to the actual positions of multiple surface sections, maintaining both pressure uniformity and position alignment.
Solution Approach 2:
While the pressing member itself is unified, the patent acknowledges the segmented nature of surface sections to be decorated and designs the flat plate-shaped rubber piece to accommodate this segmentation. The rubber piece can independently contact each surface section while maintaining overall uniformity, effectively handling the segmented decoration requirements without misalignment.
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 formation of decorative layers on large components without transfer defects, accommodating positional deviations and maintaining design accuracy, thus reducing manufacturing costs and improving the uniformity of decorative designs.
Implementation Method 1
a heated pressing member is pressed against a transfer sheet placed on a surface section to be decorated (and thereby applies heat and pressure thereto) to transfer the foil in the transfer sheet to the surface section
Implementation Method 2
the pressing member has a pressing surface configured to come in contact with the transfer sheet and constituted by a rubber piece shaped into a flat plate... which is curved to fit a general surface shape of the area to be decorated
Data Source
AI summary
The present invention provides a method of manufacturing a decorative molding with a capability to decorate a large component to be decorated. The method includes pressing a heated pressing member against an area to be decorated having a plurality of spaced-apart surface sections to be decorated, with a transfer sheet interposed between the pressing member and the area to be decorated, to transfer decorative layers to the surface section to be decorated. The area to be decorated has a maximum width of not less than 400 mm. The pressing member has a pressing surface configured to come in contact with the transfer sheet and constituted by a rubber piece shaped into a flat plate. The rubber piece has a hardness of not more than 80 degrees and a thickness of not less than 3 mm, and is curved to fit a general surface shape of the area to be decorated.