Optical Thin Film Hardening via Post-Mold UV Curing
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Solution Overview
Problem
Conventional optical thin film manufacturing processes using insert mold decoration technology face issues such as cracks, wrinkles, and fogging due to pre-hardening treatments, leading to reduced yield rates and complications in surface coating, including waste and uneven distribution of paints.
Innovation Solution
An optical thin film with a non-hardened hardenable layer is formed above the film, followed by direct printing or transfer printing of figures, and then injection molding of the plastic substrate, with the hardenable layer being hardened post-injection using UV light to prevent cracks and wrinkles, and integrating surface coating into the mold process.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If pre-hardening treatment is applied to the optical thin film before hot stamping or thermal vacuum forming, then the hardness and scratch resistance are improved, but cracks and wrinkles appear on the film during subsequent forming processes
Solution Approach 1:
The patent applies preliminary action by forming the optical thin film into the required shape (through hot stamping or thermal vacuum forming) BEFORE applying the hardening treatment. This reverses the conventional sequence where hardening is applied first, thereby avoiding cracks and wrinkles while achieving the desired shape and subsequent hardness improvement through UV curing or other hardening methods.
2Adaptability or versatility
If spray coating is used for surface decoration, then color and figures can be applied, but masking paint and adhesive tapes must be used repeatedly causing time consumption and pollution
Solution Approach 1:
The patent merges the surface decoration step with the film forming step by printing figures or colors directly onto the optical thin film during the hot stamping or thermal vacuum forming process. This integration eliminates the need for separate spray coating operations and masking procedures, significantly reducing process time and pollution while maintaining decorative versatility.
Solution Approach 2:
The patent replaces the mechanical spray coating system with a printing system that can directly deposit patterns onto the film during forming. This substitution eliminates the need for masking tapes and repeated spray applications, reducing both time consumption and environmental pollution from paint waste.
3Strength
If transparent curable coating is spray coated for protection, then scratch resistance is improved, but coating waste and uneven distribution occur causing surface roughening
Solution Approach 1:
The patent replaces the spray coating mechanical system with a direct printing or transfer printing system that applies protective coatings or decorative patterns directly onto the optical thin film during the forming process. This substitution ensures uniform distribution without the waste and surface roughening problems associated with spray coating methods.
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 increases yield rates, eliminates paint waste and uneven distribution, and simplifies processing by preventing fogging and surface roughening, while reducing manufacturing costs through energy savings and streamlined procedures.
Implementation Method 1
the optical thin film has a hardenable layer that is treated by UV light after forming the products
Data Source
AI summary
An optical thin film with high hardness is made by insert mold technology and manufacturing processes thereof. The optical thin film is applied on a surface of a plastic housing for increasing hardness of the plastic housing so as to prevent scratches. During manufacturing processes of the insert mold for producing a hard coating film, the step of hardening treatment is moved to the last step so as to avoid cracks on the optical thin film generated during the procedures. Thus, the yield rate is increased, and the manufacturing cost is reduced.