IMD Transfer Film With Register-Accurate 3D Forming Elements

Solution Overview

Problem

Existing in-mold decoration (IMD) methods require changes in injection molds for shape modifications and struggle with accurately aligning surface structures with decorative elements, leading to inefficiencies and increased costs.

Innovation Solution

A method involving a transfer film with a carrier ply and a decorative ply, where forming elements with a three-dimensional shape are applied register-accurately to the decorative ply, allowing for precise integration of haptic and tactile elements during back-injection molding, reducing the need for new molds and enabling efficient production of small batch sizes.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Adaptability or versatility

If the injection mold is changed to produce a different shape, then the shape to be produced can be changed, but the cost and time for production increase

Engineering Contradiction:

Improveshape variabilityVSAvoidproduction time

Core Design Contradiction:

Adaptability or versatilityVSLoss of time

Solution Approach 1:

The forming elements are applied to the carrier ply before the back-injection molding process. This preliminary preparation allows the shapes to be pre-positioned and registered accurately with the decorative ply, eliminating the need to change injection molds when different shapes are required. The forming elements are already in place on the transfer film when it enters the mold.

Inventive Principle:

Principle #10Preliminary action

2Adaptability or versatility

If the injection mold is changed to produce a different shape, then the shape to be produced can be changed, but the production cost increases

Engineering Contradiction:

Improveshape variabilityVSAvoidproduction cost

Core Design Contradiction:

Adaptability or versatilityVSEase of manufacture

Solution Approach 1:

The forming elements are applied to the carrier ply before the back-injection molding process. This preliminary preparation allows the shapes to be pre-positioned and registered accurately with the decorative ply, eliminating the need to change injection molds when different shapes are required. The forming elements are already in place on the transfer film when it enters the mold.

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

Instead of changing the injection mold to create different shapes, the patent uses forming elements that are applied to the carrier ply to create the desired shapes. These forming elements act as temporary molds or copies that can be easily replaced without changing the expensive injection mold, thereby reducing production costs for shape variations.

Inventive Principle:

Principle #26Copying

3Shape

If surface structures are introduced after back-injection molding, then the decorative film can be shaped, but the alignment with decorative elements becomes inaccurate

Engineering Contradiction:

Improvesurface structureVSAvoidregistration accuracy

Core Design Contradiction:

ShapeVSManufacturing precision

Solution Approach 1:

The forming elements are applied to the carrier ply before the back-injection molding process. This preliminary preparation allows the shapes to be pre-positioned and registered accurately with the decorative ply, eliminating the need to change injection molds when different shapes are required. The forming elements are already in place on the transfer film when it enters the mold.

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

The carrier ply acts as an intermediary layer between the forming elements and the decorative ply. The forming elements are applied to the carrier ply, which then transfers the shape information to the decorative ply during back-injection molding. This intermediary approach ensures accurate registration between the surface structures and decorative elements.

Inventive Principle:

Principle #24Intermediary (Mediator)

Data Source

PatentUS12350958B2Transfer film, plastic injection-molded article, and method for the production thereof

Publication Date: 2025.07.08 LEONHARD KURZ STIFTUNG & CO KG

AI summary

Methods for producing a transfer film (1), in particular IMD transfer film (1), wherein the following steps are carried out, in particular in the specified order:preparing a carrier ply (3),preparing a transfer ply (2) having a decorative ply (21), wherein the transfer ply (2) has been or is arranged on the carrier ply (3),applying one or more forming elements (40) to the carrier ply (3), wherein the one or more forming elements (40) have a three-dimensional shape and are applied register-accurately with respect to the decorative ply (21).A method for coating a plastic injection-molded article with the transfer film, as well as the transfer film and the plastic injection-molded article.