Magnetic Pattern Mold Spray Coating for 3D Pigment Pattern Formation
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Solution Overview
Problem
Existing methods for forming patterns on complex 3D shapes, such as shoes and automotive interiors, are limited by high production costs, complexity, and the inability to freely change patterns, as they require extensive mold manufacturing and large amounts of magnetic pigment.
Innovation Solution
An apparatus using a magnetic pattern mold with nonmagnetic grooves to generate magnetic field lines, combined with a spray unit applying an adhesive resin composite containing ferromagnetic pigment, allows for the easy formation of desired patterns by rearranging the magnetic pigment along predetermined magnetic field lines, enabling cost-effective and flexible pattern creation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If injection molding with electromagnet is used to form 3D magnetic pigment pattern, then pattern formation capability is improved, but manufacturing cost increases due to expensive mold and large amount of magnetic pigment required
Solution Approach 1:
The patent replaces the injection molding mechanical system with a spray coating system. Instead of injecting magnetic pigment into a mold with electromagnet, the invention sprays magnetic pigment suspension onto the article surface, allowing pattern formation without expensive mold manufacturing and reducing magnetic pigment consumption.
Solution Approach 2:
The patent changes the application method parameter from injection molding to spray coating. This parameter change enables pattern formation with minimal magnetic pigment usage and eliminates the need for costly mold fabrication, directly addressing the cost issue while maintaining pattern formation capability.
2Manufacturing precision
If injection molding with electromagnet is used to form 3D magnetic pigment pattern, then magnetic pigment arrangement is improved, but device complexity increases due to electromagnet installation in mold
Solution Approach 1:
The patent eliminates the electromagnet-mold complex system by replacing it with a spray coating system. The magnetic pigment arrangement is achieved through the natural magnetic properties of the pigment particles in the suspension, which self-organize during the spray drying process, without requiring complex electromagnet installation.
Solution Approach 2:
The magnetic pigment particles in the suspension self-arrange into patterns through their inherent magnetic properties during the spray application and drying process. This self-organization eliminates the need for external electromagnet control systems, simplifying the device while maintaining pattern formation capability.
3Manufacturing precision
If injection molding with electromagnet is used to form 3D magnetic pigment pattern, then pattern formation is improved, but adaptability decreases because pattern changes require new molds
Solution Approach 1:
The patent introduces dynamic flexibility to the pattern formation process. Instead of fixed molds, the spray coating system allows real-time pattern changes by adjusting the spray motion, nozzle positioning, or suspension properties, enabling rapid adaptation to different design requirements without manufacturing new molds.
Solution Approach 2:
The spray coating apparatus serves multiple pattern formation functions with a single device. By controlling spray parameters, motion paths, and suspension characteristics, the same apparatus can create various patterns on different articles, providing universal applicability and high adaptability.
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
This solution reduces manufacturing costs and allows for easy pattern changes by using a flexible magnetic pattern mold and adhesive resin composite, enhancing mechanical strength and enabling 3D optical illusion effects while maintaining pattern integrity.
Implementation Method 1
a magnetic pattern mold having nonmagnetic pattern grooves engraved in a predetermined pattern, and providing predetermined magnetic field lines on a pattern-forming object surface of an article by generating magnetism in areas outside the nonmagnetic pattern grooves
Implementation Method 2
a spray unit spraying an adhesive resin composite containing a ferromagnetic pigment onto the pattern-forming object surface of the article, wherein a predetermined magnetic pigment pattern is formed while the magnetic pigment of the adhesive resin composite that is applied to the pattern-forming object surface of the article is rearranged along magnetic field lines generated by the magnetic pattern mold
Data Source
AI summary
There is provided an apparatus for forming a magnetic pigment pattern on an article. The apparatus includes: a magnetic pattern mold having nonmagnetic pattern grooves engraved in a predetermined pattern and providing predetermined magnetic field lines on a pattern-forming object surface of an article by generating magnetism in areas outside the nonmagnetic pattern grooves; and a spray unit spraying an adhesive resin composite containing a ferromagnetic pigment onto the pattern-forming object surface of the article. A predetermined magnetic pigment pattern is formed while the magnetic pigment of the adhesive resin composite that is applied to the pattern-forming object surface of the article is rearranged along magnetic field lines generated by the magnetic pattern mold.