Laminate Sheet Maintaining 3D Patterns During Injection Molding
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing laminate sheet technologies fail to maintain three-dimensional patterns with depth feeling and variation in thickness during the production and use of molded bodies, as they either lose concavo-convex shapes due to heat or pressure, or require costly mold changes for design variations, and lack sufficient depth perception due to monotonous convex patterns.
Innovation Solution
A laminate sheet comprising a transparent resin layer, a colored layer, and a pattern layer made of ionizing radiation curable resin with a concavo-convex shape and continuously varied thickness, integrated with a molded resin layer using injection molding, where the pattern layer has a softening temperature of 140 to 160°C and the surface is reshaped to be flat, allowing for a design with three-dimensionality and depth feeling.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Shape
If a concavo-convex shape is imparted on the surface of a laminate sheet by embossing or other processes, then a three-dimensional pattern is obtained, but the concavo-convex shape is often not maintained owing to heat or pressure applied in the heat molding for producing the shaped body or in the film insert molding
Solution Approach 1:
The patent applies preliminary embossing to the mold cavity surface before the molding process, so that the three-dimensional pattern is imprinted on the laminate sheet during molding itself, rather than pre-imparting the shape to the laminate sheet which would then be subjected to heat and pressure that could distort it. This preliminary preparation of the mold ensures the pattern is formed under controlled conditions.
Solution Approach 2:
The patent uses the mold cavity surface as an intermediary to transfer the three-dimensional pattern to the laminate sheet. By embossing the mold cavity with the desired pattern and then pressing the laminate sheet against it during molding, the pattern is transferred without directly applying heat or pressure to pre-shaped laminate, thus maintaining pattern integrity.
2Shape
If the inner surface of a mold cavity is subjected to emboss processing to impart a concavo-convex shape to the part surface, then a three-dimensional pattern is obtained, but a mold is required for each design, causing a problem of production cost increase
Solution Approach 1:
The patent creates a universal mold cavity that can produce different three-dimensional patterns by using a single base mold structure. The embossing process allows the same mold to generate various patterns (metal hairline, wood grain, carbon cloth, etc.) by changing the embossing template or parameters, making the mold multi-functional and eliminating the need for separate molds for each design.
Solution Approach 2:
The patent enables design changes by modifying embossing parameters such as pressure, temperature, and embossing pattern depth, rather than requiring physical mold changes. This allows a single mold cavity to produce multiple design variations through parameter adjustment, significantly reducing production costs for design variations.
3Reliability
If a transparent protective layer is applied on the surface having the concavo-convex shape and further covered with a flat transparent sheet, then the three-dimensionality is maintained during production, but the pattern layer does not show depth feeling since the pattern layer itself has almost no transparency and has little variation in thickness
Solution Approach 1:
Instead of adding layers on top of a flat pattern layer to create three-dimensionality (which results in monotone convex portions), the patent inverts the approach by embossing the mold cavity itself with the three-dimensional pattern. This allows the pattern layer to have genuine thickness variation and depth feeling, as the embossing creates actual concavo-convex structures rather than superficial markings.
Solution Approach 2:
The patent uses a composite structure where the pattern layer is formed as part of the molded body itself, integrating the pattern layer with the base material through the embossed mold cavity. This creates a unified composite structure with genuine three-dimensional features and depth variation, rather than separate layers that lack integration.
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 laminate sheet effectively maintains three-dimensional patterns with depth feeling and variation in thickness during molding, ensuring the molded body has a flat surface with enhanced three-dimensionality and depth perception, while reducing production costs by eliminating the need for frequent mold changes.
Implementation Method 1
a pattern layer which is laminated on the other surface of the resin layer, is made of an ionizing radiation curable resin, and has optical transparency
Implementation Method 2
heating the laminate sheet to a temperature not lower than the softening point of the resin layer and not higher than the softening point of the pattern layer, while applying a press
Implementation Method 3
a resin layer which has optical transparency and a softening temperature of 120° C. or lower
Data Source
AI summary
Provided is a laminate sheet in which, on one surface of a resin layer having optical transparency, a colored layer and a backing layer are sequentially laminated, and on the other surface of the resin layer, a pattern layer made of an ionizing radiation curable resin and having optical transparency is laminated. The pattern layer has a softening temperature of 140 to 160° C., and the resin layer, the colored layer, and the backing layer have softening temperatures of 120° C. or lower. The surface of the pattern layer has a concavo-convex shape and the thickness thereof is continuously varied.