Mold Alignment Mark for Decorative Film Positioning
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Solution Overview
Problem
The existing method for decorative molding requires time-consuming alignment checks and adjustments every time the mold is replaced, especially for deep-drawing shapes, due to positional displacement of the decorative pattern, leading to increased preparation time and reduced accuracy.
Innovation Solution
The method involves using a camera to image both mold-side and film-side alignment marks, allowing for precise positioning of the film relative to the mold, reducing the need for frequent alignment checks by using the mold-side alignment mark as a reference for positioning the film before resin injection.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If manual alignment checks and adjustments are performed every time the mold is replaced, then positioning accuracy can be maintained, but preparation time increases significantly
Solution Approach 1:
The mold-side alignment mark is prepared in advance on the mold before each molding operation. This preliminary marking allows for quick and accurate positioning of the film without requiring time-consuming manual alignment checks when the mold is replaced, thus reducing preparation time while maintaining positioning accuracy.
2Manufacturing precision
If the film is positioned manually before each molding, then positioning accuracy is maintained, but operational complexity and time consumption increase
Solution Approach 1:
The mold-side alignment mark serves as a self-aligning reference that automatically guides the film positioning process. By having the alignment mark already positioned on the mold, the system eliminates the need for complex manual alignment operations, making the process simpler and faster while maintaining accuracy.
3Manufacturing precision
If alignment marks are used for positioning, then positioning accuracy improves, but the complexity of the positioning system increases
Solution Approach 1:
The alignment function is extracted from the complex positioning system and embodied in a simple, pre-prepared mark on the mold. This isolated alignment mark serves as a reference without requiring complex positioning mechanisms, thereby improving accuracy while minimizing system complexity.
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 approach significantly reduces preparation time and improves the accuracy of the decorative pattern positioning on molded articles by eliminating the need for manual displacement corrections and realignment during mold changes, particularly for deep-drawing shapes.
Implementation Method 1
imaging a mold-side alignment mark recorded in the mold and a film-side alignment mark recorded in the film by a camera
Implementation Method 2
injecting resin into the mold in a mold closed state in which the film is sandwiched between the first mold and the second mold and cooling the resin to form a molded article
Implementation Method 3
transferring a decorative pattern recorded on the film to a surface of the molded article
Data Source
AI summary
A method for decorative molding capable of reducing a preparation time at the time of replacing a mold and expecting improvement in positioning accuracy of a decorative pattern in a molded article includes supplying a film on which a decorative pattern is formed between a first mold and a second mold in a mold open state of a mold, imaging a mold-side alignment mark recorded in the mold and a film-side alignment mark recorded in the film by a camera, positioning the film with respect to the mold by moving the film so that the film-side alignment mark comes close to the mold-side alignment mark, injecting resin into the mold in a mold closed state in which the film is sandwiched between the first mold and the second mold and cooling the resin to form a molded article and opening the mold and taking out the molded article in which the decorative pattern of the film is transferred to the surface.