Molded Resin Product With Segmented Shielding Layer
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Solution Overview
Problem
Molded resin products with visible patterns require flexibility to accommodate curved joint surfaces and must be lightweight for portable applications like smart keys, but existing designs fail to balance these requirements effectively.
Innovation Solution
A molded resin product structure comprising a cover layer, a decorative layer with a first color, a shielding layer of a second color, and a resin base layer with varying thicknesses to create a pattern and base portion, where the base portion is thinner than the pattern portion, allowing for flexibility and reduced weight.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If the design layer is made thicker to maintain structural integrity and appearance, then the strength and appearance quality improve, but the flexibility decreases making it difficult to join to curved surfaces
Solution Approach 1:
The design layer is segmented into two distinct regions: a base portion with smaller layer thickness and a pattern portion with larger layer thickness. This segmentation allows each region to serve different functions - the base portion provides flexibility for joining to curved surfaces, while the pattern portion maintains structural integrity and appearance quality.
Solution Approach 2:
Different regions of the design layer are given different thickness properties locally. The base portion has a smaller thickness to provide flexibility, while the pattern portion has a larger thickness to maintain strength and appearance. This local differentiation of properties resolves the contradiction between overall flexibility and localized structural requirements.
2Strength
If the layer thickness is increased to improve appearance quality, then the appearance quality improves, but the weight increases making the product heavier
Solution Approach 1:
The design layer is divided into base portion and pattern portion with different thicknesses. By segmenting the layer, the patent minimizes the total thickness (and thus weight) while still maintaining adequate thickness in the pattern portion to ensure appearance quality is not compromised.
Solution Approach 2:
The thickness property is locally optimized - the base portion has smaller thickness to reduce weight, while the pattern portion maintains larger thickness to preserve appearance quality. This local quality differentiation allows weight reduction without sacrificing appearance.
3Adaptability or versatility
If the design layer is made thinner to improve flexibility and reduce weight, then the flexibility and weight improve, but the appearance quality deteriorates
Solution Approach 1:
By segmenting the design layer into base portion and pattern portion, the patent ensures that the pattern portion maintains sufficient thickness to preserve appearance quality, while the base portion can be thinner to provide flexibility. This segmentation prevents appearance deterioration even when parts of the layer are made thinner.
4Weight of moving object
If the overall layer thickness is reduced to reduce weight, then the weight decreases, but the flexibility may not be sufficient for curved surfaces
Solution Approach 1:
The design layer is segmented such that the base portion has smaller thickness to reduce weight, while the pattern portion maintains larger thickness. This segmentation ensures that the overall weight is reduced while the pattern portion provides sufficient structural support and the thinner base portion enhances flexibility for joining to curved surfaces.
Data Source
AI summary
A molded resin product includes a design layer including a decorative layer having a first color, a shielding layer having a second color different from the first color, and a resin base layer. A cover layer formed of a polymer film is disposed close to one end of the design layer. Part of the decorative layer exposed from the shielding layer serves as an exposed region. The exposed region and part of the shielding layer constitute a pattern portion presenting a predetermined figure or character when viewed in plan through the cover layer. The rest of the shielding layer constitutes a base portion. The layer thickness of the base portion is set smaller than the layer thickness of the pattern portion in a region thereof where the shielding layer is formed.