Laser-Textured Resin Matte Surfaces for Uniform Low Gloss
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Solution Overview
Problem
Existing methods for achieving low glossiness on resin molded articles face limitations due to material restrictions, shape complexities, and issues with coating peeling, embossment transfer inefficiencies, and non-uniform roughening, particularly in precision components.
Innovation Solution
A resin molded article with a matte surface formed by laser light irradiation, featuring grooves with a depth-to-width ratio (D/W) of 0.2 to 3.5, where the depth (D) is 150 µm or greater and the width (W) is 400 µm or less, using a thermoplastic resin composition that may include laser light absorbents and dark colorants.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Illumination intensity
If coating is performed with a matte coating or light shielding coating, then glossiness is reduced, but film uniformity deteriorates and coating may peel off
Solution Approach 1:
The patent replaces the coating process (chemical/physical deposition) with laser beam processing (optical ablation). The laser beam directly removes material to create the matte surface texture, eliminating the need for separate coating materials and processes. This substitution resolves the film uniformity and peeling issues inherent in coating methods.
Solution Approach 2:
The patent changes the surface properties by controlling laser processing parameters (beam power, scanning speed, pulse duration) to create specific microstructures. By adjusting these parameters, the surface roughness and light scattering properties are directly controlled, achieving the desired matte effect without external coatings.
2Shape
If a metal die is subjected to fine emboss processing, then surface texture is transferred, but resin fluidity prevents sufficient permeation and transfer
Solution Approach 1:
The patent replaces the mechanical embossing process with laser beam processing. Instead of relying on resin fluidity to fill embossment cavities during molding, the laser beam directly ablates the cured resin surface to create the desired texture. This eliminates the transfer inefficiency caused by poor resin permeation.
3Illumination intensity
If sand blasting or wet blasting is used to roughen the surface, then glossiness is reduced, but uniform roughening control becomes difficult
Solution Approach 1:
The patent replaces stochastic mechanical blasting processes with a controlled laser beam process. The laser can be precisely scanned along predetermined paths with controlled parameters, ensuring uniform material removal and consistent surface texture across the entire treated area, eliminating the variability inherent in blasting methods.
Solution Approach 2:
The laser processing system incorporates real-time monitoring and control mechanisms that adjust processing parameters based on feedback signals. This ensures consistent ablation depth and surface texture uniformity, maintaining tight tolerances that cannot be achieved with open-loop blasting processes.
4Strength
If laser light irradiation is used to form grooves, then bonding strength is improved, but surface glossiness is not optimized for light shielding
Solution Approach 1:
The patent merges two previously separate functions into a single laser processing operation: creating mechanical interlocking grooves for bonding strength and creating light-scattering microstructures for matte finish. The laser beam simultaneously achieves both objectives by controlling ablation patterns and depths, eliminating the need for separate bonding preparation steps.
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 method enables easy, uniform, and durable matte surface formation with low glossiness, suitable for various materials and shapes, without peeling, and is applicable as a light shielding member in optical equipment.
Implementation Method 1
the matte surface (10) is a recess/projection surface having a plurality of grooves formed by laser light irradiation
Data Source
Figure 1~2
AI summary
Provided is a resin molded article having a matte surface. The resin molded article is obtained by molding a thermoplastic resin composition, and at least part of the resin molded article has a matte surface having a 60-degree glossiness of 1.5% or less. The matte surface is a recess/projection surface having a plurality of grooves formed by laser light irradiation, or a flat surface from which an entire surface layer portion is removed by laser light irradiation.