Flocked Doll Frame Electrostatic Assembly Without Masking
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Solution Overview
Problem
Small dolls with flocked surfaces face challenges in maintaining an excellent aesthetic appearance due to difficulties in applying and securing small masking seals, which often lead to peeling issues and incomplete flocking.
Innovation Solution
A doll manufacturing method involving a frame member and part members made of molded resin products, where electrostatic flocking is applied to surface regions including fitting and exposed portions without the need for masking, allowing for a seamless and aesthetically pleasing finish.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If a small cut-out masking seal is applied to prevent flocking on attachment portions, then flocking can be controlled on small dolls, but the seal is easily peeled off and cannot maintain excellent aesthetic appearance
Solution Approach 1:
The invention extracts and eliminates the masking seal from the process entirely. Instead of using a masking seal to control flocking regions, the patent uses a multi-component assembly where the flocking is applied to the frame member and exposed portions, while the part member with fitting portion is assembled separately. This extraction of the masking seal resolves the adhesion reliability issue while maintaining flocking control precision through the design of the assembly structure itself.
Solution Approach 2:
The invention segments the doll into a frame member and separate part members, where the frame member includes exposed portions that are flocked, and part members with fitting portions that are assembled later. This segmentation allows flocking to be applied to specific regions (frame member and exposed portions) without requiring masking seals on attachment portions, as the fitting portions are designed to be assembled after flocking. This resolves both the adhesion reliability issue and maintains manufacturing precision.
2Manufacturing precision
If masking seal is used to prevent flocking on attachment portions, then flocking can be controlled, but the process becomes complex and time-consuming for small dolls
Solution Approach 1:
The invention extracts the masking seal and associated masking process from the manufacturing workflow. By designing the frame member with exposed portions that are intentionally flocked and separate part members with fitting portions that are assembled later, the patent eliminates the need for masking seals entirely. This extraction simplifies the manufacturing process while maintaining precise control over which regions are flocked, as the flocking is applied to the frame member and exposed portions before assembly.
Solution Approach 2:
The invention performs preliminary action by applying flocking to the frame member and exposed portions before assembling the part members. This preliminary flocking action on the frame member and exposed portions, followed by the assembly of part members with fitting portions, eliminates the need for masking seals during the flocking process. This preliminary action approach simplifies the overall process while maintaining precise flocking region control.
3Manufacturing precision
If masking seal is applied on small doll surfaces, then flocking can be controlled, but the seal peels off easily resulting in incomplete flocking
Solution Approach 1:
The invention extracts the masking seal from the process, eliminating the source of peeling and incomplete flocking. By using a frame member with exposed portions that are flocked and separate part members with fitting portions that are assembled later, the patent achieves complete and reliable flocking coverage without the need for masking seals. This extraction resolves both the manufacturing precision issue regarding flocking coverage and the ease of manufacture issue regarding process reliability.
Solution Approach 2:
The invention segments the doll structure into a frame member with exposed portions and separate part members with fitting portions. This segmentation allows the flocking process to be applied reliably to the frame member and exposed portions before assembly, ensuring complete flocking coverage without the interference of masking seals. The segmentation creates a clear workflow where flocking is performed on designated regions, then parts are assembled, ensuring both manufacturing precision and process reliability.
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 enables the production of small dolls with excellent aesthetic appearances by ensuring uniform and secure flocking across all relevant surfaces, even on small dolls, without the need for masking seals.
Implementation Method 1
a surface region of the frame member, the surface region including at least a part of a surface of the first fitting portion and at least a part of a surface of the exposed portion, is formed as a first flocked region on which short fibers are electrostatically flocked
Data Source
AI summary
A doll includes: a frame member made of a molded product of a resin material and including a first fitting portion and an exposed portion; and at least one part member made of a molded product of a resin material and including a first part member. The first part member includes a first fitted portion configured to be fitted with the first fitting portion. A surface region of the frame member including at least a part of a surface of the first fitting portion and at least a part of a surface of the exposed portion is formed as a first flocked region on which short fibers are electrostatically flocked.