Injection Molded Composite with Integrated Lacquer Coating
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Solution Overview
Problem
Existing composite systems of metal foils and polymers require separate steps for joining and attaching fastening elements, making the process complex and costly.
Innovation Solution
A process involving injection molding of resin onto a plastic film in a mold, followed by injecting lacquer into a gap formed between the molded article and a supplemental mold half, allowing for direct bonding and integration of fastening elements during production.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If separate steps are used to join layers and attach fastening elements, then bonding strength and assembly reliability are improved, but manufacturing complexity and production time increase
Solution Approach 1:
The patent combines multiple separate manufacturing steps into a single integrated injection molding process. Fastening elements, adhesive layers, and the main article are all formed simultaneously in one molding cycle, eliminating the need for separate joining and assembly steps while maintaining bonding strength through direct integration of components.
Solution Approach 2:
The fastening elements and adhesive layers are pre-formed as integral parts of the molded article during the injection molding process itself. This preliminary formation of bonding structures eliminates the need for subsequent separate bonding operations, reducing manufacturing complexity while ensuring reliable attachment.
2Manufacturing precision
If separate steps are used to join layers and attach fastening elements, then assembly precision is improved, but production efficiency decreases
Solution Approach 1:
The patent merges layer joining and fastening element attachment into a single injection molding operation. All components are formed and assembled in one continuous process without intermediate steps, maintaining precise positioning through mold-based alignment while dramatically increasing production efficiency by eliminating sequential operations.
Solution Approach 2:
The injection molding process operates continuously to form the article, adhesive layers, and fastening elements in an uninterrupted sequence. The molten material flows continuously through the mold cavities, ensuring consistent precision while maximizing production throughput without idle time between operations.
3Reliability
If multiple separate manufacturing steps are used, then quality control is improved, but cost effectiveness decreases
Solution Approach 1:
The patent consolidates multiple manufacturing steps into one injection molding process, reducing the number of handling operations, tooling changes, and quality inspection points. This integration maintains quality control through consistent mold-based manufacturing while reducing overall production costs by eliminating redundant process steps and associated overhead.
4Manufacturing precision
If edges of layers require rework, then bonding quality is improved, but manufacturing time increases
Solution Approach 1:
The adhesive layers and fastening elements are pre-formed with precise edge positioning during the injection molding process itself. The mold cavities ensure accurate alignment and complete coverage of layer edges, eliminating the need for subsequent edge rework or trimming operations while maintaining high bonding quality throughout the entire article.
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 cost-effective and technically simple production of composite moldings with adhesive layering and integrated fastening elements, suitable for applications like vehicular mirrors.
Implementation Method 1
to which surface adherently bonded is said plastic film
Implementation Method 2
curing the lacquer to produce a lacquered molded article
Data Source
AI summary
A process for the production of a molded article is disclosed. The process comprise a) placing a plastic film abutting the inside wall of a first half of a mold, said mold including a first and second halves, b) combining said second half with said first half in a manner creating a mold cavity, c) injecting resin into said cavity to produce an article to which surface adherently bonded is said plastic film, d) separating one of the halves from the other half, said article remaining with said other half, e) combining a supplemental half with said other half in a manner forming a gap between the inner wall of said supplemental half and the surface of said molded article, f) injecting lacquer into said gap, g) curing the lacquer to produce a lacquered molded article, and h) cooling and removing the lacquered molded article from the mold. The inventive process is particularly suitable for making vehicular mirrors.