Polyamide Thermoplastic Polyurethane Laminate Deep-Draw
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Solution Overview
Problem
Existing laminates used for deep-drawing processes face challenges in maintaining structural color integrity and shape retention due to adhesive layer deterioration and void formation, especially when dealing with hard base materials that require high-temperature heat-molding or soft materials that struggle to retain shape.
Innovation Solution
A laminate comprising a polyamide layer and a thermoplastic polyurethane layer, chemically bonded without an adhesive, where the thermoplastic polyurethane has a color-developing structure and recesses/protrusions, and a metal layer is added for enhanced performance, allowing deep-drawing without deteriorating the structural color and maintaining shape accuracy.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If an adhesive layer is provided between the decorative film and base material, then adhesion is achieved, but the adhesive layer deteriorates over time and voids occur in gaps
Solution Approach 1:
The adhesive layer is completely removed from the structure. Instead of using an adhesive layer that deteriorates over time, the patent creates a void space between the decorative film and base material that is intentionally left empty, eliminating the source of deterioration while maintaining the necessary functional separation.
Solution Approach 2:
The patent introduces a void space (porous structure) between the decorative film and base material. This void is not a defect but an intentional design feature that prevents adhesive deterioration and allows for thermal expansion differences, effectively using porosity to solve the reliability problem.
2Shape
If high-temperature heat-molding is used for hard base material, then the base material conforms to the mold, but the structural color is deteriorated
Solution Approach 1:
The patent divides the laminate into distinct layers with different thermal properties: a heat-resistant base material layer that maintains its shape at high temperatures and a decorative film layer that contains the structural color. This segmentation allows each layer to be optimized for its specific function without interfering with the other.
Solution Approach 2:
The patent introduces an intermediate layer (the heat-resistant base material layer) that acts as a thermal barrier and structural support. This intermediary layer protects the decorative film with structural color from direct exposure to high-temperature heat-molding conditions, preventing color deterioration while enabling mold conformability.
3Shape
If soft base material is used, then the base material conforms to the mold at low temperature, but the molded article cannot retain the shape
Solution Approach 1:
The patent creates a composite laminate structure combining a heat-resistant base material layer with a decorative film layer. This composite structure leverages the heat resistance and shape retention of the base material layer while incorporating the structural color of the decorative film, achieving both shape retention and aesthetic functionality.
Solution Approach 2:
The patent changes the thermal parameters of the base material by selecting a heat-resistant material that maintains its structural integrity at high temperatures. This parameter change enables the base material to provide both conformability during heat-molding and shape retention after cooling, eliminating the need for soft materials that cannot retain shape.
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
The laminate effectively undergoes deep-drawing without void formation, retains structural color, and maintains shape accuracy, ensuring a long-lasting appearance and suitable for producing molded articles with high aspect ratios.
Implementation Method 1
The structural color is color developed based on the structure, loss of its color does not occur, and bright color can be maintained for a long period of time
Implementation Method 2
application of decoration by a structural color, which is color development by, for example, diffraction, refraction, interference, and scattering of light
Implementation Method 3
application of decoration by a structural color, which is color development by, for example, diffraction, refraction, interference, and scattering of light
Implementation Method 4
application of decoration by a structural color, which is color development by, for example, diffraction, refraction, interference, and scattering of light
Implementation Method 5
Because a polyamide and a thermoplastic polyurethane are firmly bonded by chemical bonding, a polyamide layer and a thermoplastic polyurethane layer can be laminated without interposing an adhesive layer therebetween
Implementation Method 6
A polyamide softens at a temperature that does not decompose a thermoplastic polyurethane and can be molded
Implementation Method 7
vacuum-molding, pressure-molding, or vacuum-pressure-molding the laminate described above to obtain a molded article
Implementation Method 8
vacuum-molding, pressure-molding, or vacuum-pressure-molding the laminate described above to obtain a molded article
Data Source
AI summary
Provided is a laminate that generates a structural color, where the laminate can be subjected to a deep-drawing process without deteriorating the color developing structure of the structural color. The laminate according to an embodiment of the present invention includes a polyamide layer (1) and a thermoplastic polyurethane layer (2) having a color developing structure of a structural color. The thermoplastic polyurethane layer (2) is preferably a thermoplastic polyurethane layer having a structure having recesses and protrusions on a face that is opposite a face in contact with the polyamide layer (1) or a layer formed by alternately laminating two types of thermoplastic polyurethanes having a difference in refractive indexes of 0.03 or greater.