Plastic Ball Shimmer via Local Non-Opaque Coloring
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Solution Overview
Problem
The production of printed plastic balls with a metallic shimmer effect is costly due to the need for additional clear lacquer layers and limited color options in existing methods, which obscure the shimmering surface when opaque colors are applied.
Innovation Solution
A method involving a working mixture with luster effect pigments, where non-opaque colors are applied exclusively to specific areas of the semi-finished product, allowing the pigments to shimmer through and create a metallic effect without additional clear coats, using thermoplastics like polyvinyl chloride and heating to ensure uniform pigment distribution.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If opaque colors are applied to the semi-finished product, then the printing coverage is improved, but the metallic shimmer effect is lost
Solution Approach 1:
The patent applies different color properties to different areas of the ball surface. Non-opaque colors are used in specific areas where metallic shimmer is desired, while opaque colors can be used in other areas for solid color coverage. This local differentiation allows both printing coverage and metallic shimmer effects to coexist in different regions of the same product.
Solution Approach 2:
The patent utilizes colors with varying transparency properties (non-opaque vs. opaque) to achieve different visual effects. By selecting non-opaque colors that allow the underlying metallic pigments to show through, the patent creates areas with metallic shimmer while maintaining color coverage, thus resolving the contradiction between printing coverage and shimmer effect.
2Illumination intensity
If clear lacquer layers are applied to achieve metallic effect, then the appearance is refined, but the manufacturing cost increases
Solution Approach 1:
The patent replaces expensive clear lacquer layers with a more cost-effective solution: non-opaque colors applied directly to the surface. These colors achieve the desired metallic shimmer effect without requiring additional clear coat applications, thereby reducing the number of manufacturing steps and associated costs while maintaining the refined metallic appearance.
Solution Approach 2:
The patent uses non-opaque colors with specific transparency properties to create metallic shimmer effects directly, eliminating the need for separate clear lacquer coating steps. This color-based approach to achieving metallic effects reduces manufacturing complexity and cost while maintaining the desired visual appearance.
3Illumination intensity
If additional clear lacquer layers are applied, then the metallic effect is enhanced, but the number of printing process steps increases
Solution Approach 1:
The patent combines the functions of color application and metallic effect creation into a single step by using non-opaque colors that inherently provide both color coverage and shimmer effects. This merging eliminates the need for separate clear lacquer application steps, reducing the total number of printing process steps while achieving the desired metallic effect.
Solution Approach 2:
The patent uses non-opaque colors with specific optical properties to simultaneously achieve color coverage and metallic shimmer effects in one application step, eliminating the need for additional clear coat steps and thereby reducing the complexity of the printing process.
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 reduces manufacturing costs by eliminating the need for expensive metallic paints and clear lacquers, while achieving a noble appearance with a metallic effect through the use of commercially available pigments, allowing for multicolored patterns and reduced ink consumption.
Implementation Method 1
The pigments, which have a luster effect, shimmer through a non-opaque color in at least one area 28, 32, 36
Implementation Method 2
the pigments shimmer through the color layer, creating a metallic effect
Implementation Method 3
The working mixture 2 or an intermediate product produced therefrom is heated
Implementation Method 4
heating can change the formability of the working mixture or the intermediate product
Data Source
Figure 1a~3b
Figure 4
AI summary
A method for producing plastic balls, the method comprising the following steps: producing a working mixture comprising at least one plastic; adding pigments to the working mixture which have a glossy effect; forming a semi-finished product 16 from the working mixture; applying color to areas 28, 30, 32, 34, 36, 38, 40, 42, 44 of the semi-finished product 16; the method being characterized in that at least one non-opaque color is applied exclusively to at least one area 28, 32, 36 of the semi-finished product.