Multilayer Body for Decorated Plastic Articles
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Solution Overview
Problem
Conventional multi-layer bodies for producing decorated plastic articles with surface relief are inefficient in terms of production speed and flexibility, particularly in deep-drawing processes, and often result in contamination of tool surfaces leading to undesirable surface effects.
Innovation Solution
A multi-layer body comprising a relief film with a structural layer between two carrier films, allowing for detachment and independent curing of the decorative layer, which avoids contamination of tool surfaces and enables faster, more cost-effective production by allowing the structural layer to emboss the decorative layer without direct contact.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If the structural layer is in direct contact with the tool surface during injection molding, then the surface relief can be formed on the plastic article, but the tool surface becomes contaminated leading to undesirable surface effects
Solution Approach 1:
The patent introduces a release layer as an intermediary between the structural layer and the tool surface. This release layer allows the structural layer to be transferred to the plastic article while preventing direct contact and contamination of the tool surface. The release layer is designed to have low adhesion to both the tool surface and the structural layer, enabling clean separation after transfer.
Solution Approach 2:
The multi-layer body is segmented into distinct functional layers: a structural layer containing the relief pattern, a release layer preventing tool contamination, and optionally a carrier layer for support. This segmentation allows each layer to perform its specific function independently, with the release layer specifically addressing the contamination problem while the structural layer forms the surface relief.
2Ease of manufacture
If conventional multi-layer bodies are used, then decoration can be applied to plastic articles, but production speed is slow and flexibility for deep-drawing processes is poor
Solution Approach 1:
The patent merges the structural layer with the decorative layer into a single integrated multi-layer body that can be applied in one step. The structural layer and decorative layer are combined such that the same operation simultaneously transfers both the relief pattern and the decoration to the plastic article, eliminating sequential processing steps and improving production speed.
Solution Approach 2:
The patent modifies the physical and chemical parameters of the multi-layer body to enhance its flexibility and adaptability. The layers are designed with appropriate thicknesses, adhesive properties, and thermal characteristics that enable the system to accommodate deep-drawing processes and various injection molding conditions, thereby improving both flexibility and production efficiency.
3Adaptability or versatility
If the structural layer is cured before joining with the decorative layer, then independent curing is possible, but the joining process becomes more complex
Solution Approach 1:
The patent applies preliminary action by pre-curing the structural layer before joining it with the decorative layer. This pre-curing of the structural layer stabilizes the relief pattern and prevents deformation during subsequent handling and joining operations. The structural layer is cured to a sufficient degree to maintain its shape, while the decorative layer can then be joined and cured independently or simultaneously.
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 enhances production efficiency and flexibility by preventing tool surface contamination, allowing for precise matching of haptic structures with decor, and enabling faster, more cost-effective production of decorated plastic articles with improved surface relief.
Implementation Method 1
the structural layer embosses a relief in the decorative layer
Implementation Method 2
The structural layer is arranged between the first carrier film and the second carrier film, the multi-layer body has a film body which includes the relief film and can be detached from the at least one decorative layer
Data Source
Figure 1
Figure 2a
Figure 2b
AI summary
The invention relates to a multilayer body (100) for producing a decorated plastic article (50) having a surface relief (40). The multilayer body (100) comprises a relief film (1) having a first carrier film (2) and a structural layer (3) disposed on one side of the first carrier film (2). The multilayer body (100) further comprises a multilayer film (5) having a second carrier film (10) and at least one decorative layer (12, 14). The structural layer (3) is thereby disposed between the first carrier film (2) and the second carrier film (10). The multilayer body (100) further comprises a film body (19) comprising the relief film (1) that can be separated from the at least one decorative layer (12, 14), and the at least one decorative layer (12, 14) is deformably implemented by the structural layer (3) formed as an embossed structure. The invention further relates to a method for producing such a multilayer body (100), and to two methods for producing a decorated plastic article (50) comprising a surface relief (40) using such a multilayer body (100).