Latent Image Laminated Fabric for Crack-Resistant 3D Covers
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Solution Overview
Problem
Existing materials and methods for forming 3D-shaped cover products, such as mobile phone cases, suffer from issues like cracking, warping, and high defect rates due to residual stress and interfacial stress during the 3D forming process, and lack the ability to create diverse design expressions with high surface gloss and durability.
Innovation Solution
A laminated fabric is created by applying a pattern coating layer and a separately prepared FG film with a latent pattern layer on a plastic substrate, followed by UV irradiation to transfer the pattern and alleviate residual stress, resulting in a fabric with high surface hardness and crack resistance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If glass panel is used to achieve high surface gloss and durability, then surface hardness and design appearance are improved, but 3D forming capability and production cost worsen
Solution Approach 1:
The patent uses a composite structure consisting of a plastic substrate (PC or ABS) combined with a pattern coating layer. This composite material approach allows the base plastic to provide 3D forming capability while the pattern coating layer provides high surface hardness and gloss, thus resolving the contradiction between surface hardness and 3D forming capability.
2Strength
If Glastic (PC-PMMA composite sheet) is used to achieve high hardness and ductility, then strength and flexibility are improved, but surface crack resistance during 3D forming worsens
Solution Approach 1:
The patent changes the material parameters by using a specific plastic substrate (PC or ABS) with controlled properties and combining it with a pattern coating layer. This parameter optimization prevents surface cracks during 3D forming while maintaining high hardness and ductility, resolving the reliability issue with Glastic materials.
3Ease of manufacture
If plastic injection panels are used to achieve low cost and ease of manufacture, then manufacturing cost and ease of production are improved, but surface gloss and scratch resistance worsen
Solution Approach 1:
The patent combines a plastic substrate (maintaining low cost and ease of manufacture) with a pattern coating layer (providing high surface gloss and scratch resistance). This composite structure resolves the contradiction by allowing each layer to contribute its advantageous properties.
4Strength
If metal panels are used to achieve strength and durability, then mechanical strength is improved, but cost and wireless communication performance worsen
Solution Approach 1:
The patent uses a plastic substrate with pattern coating layer as a cost-effective alternative to metal panels. The plastic-based composite provides sufficient mechanical strength while being cheaper and not interfering with wireless communication, thus resolving the contradiction between strength and cost/communication performance.
5Shape
If UV imprinting with heat and pressure is applied to achieve 3D shaping, then shape formation is improved, but surface crack resistance worsens
Solution Approach 1:
The patent applies UV irradiation to cure the pattern coating layer before the 3D forming process. This preliminary action strengthens the coating layer, making it more resistant to cracks during the subsequent heat and pressure forming process, thus resolving the contradiction between 3D shaping capability and surface crack resistance.
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 laminated fabric prevents cracks in 3D-shaped portions, achieves a surface hardness of 3 H or higher, and allows for various patterns, enhancing durability and design expression, suitable for protecting surfaces of mobile, electronic, and automotive products.
Implementation Method 1
followed by ultraviolet irradiation. The FG film is then peeled off from the laminated fabric, exposing the pattern coating layer on the surface
Data Source
AI summary
Provided is a fabric comprising a plastic substrate with an upper protective film on one surface and a lower protective film on the opposite surface. A laminated fabric is obtained by laminating, on the one surface of the plastic substrate from which the upper protective film has been removed, an FG film composed of a pattern coating layer, a separately-prepared latent image pattern layer and a base film layer is laminated, and then irradiating same with ultraviolet rays. Furthermore, the latent image patterned-fabric, of which the FG film has been peeled off and removed from the laminated fabric such that the pattern coating layer is exposed at the surface, has crack resistance for a 3D-shaped part and scratch resistance of a high surface hardness of 3 H or higher during a 3D molding process in which a film of a plastic material is molded through heat and pressure after UV imprinting.