Polymer Insert Application Mold for Adhesion and Texture
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Solution Overview
Problem
Existing methods for applying polymer inserts onto supports, such as silk-screen printing, injection molding, and high-frequency welding, face issues like the need for flat surfaces, high costs, limited thickness, aesthetic defects, and incomplete adhesion, which hinder industrial efficiency and product quality.
Innovation Solution
A method using a mold with a base and cover that defines a mould impression with a closing edge to apply a polymer mixture onto a support layer, ensuring tightness and surface texture reproduction, allowing for perfect adhesion and aesthetic quality, and utilizing a spraying device for polymerization without requiring specialized labor or equipment.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If injection or micro-injection molding is used to apply polymer inserts, then the inserts can be applied with good adhesion, but the cost of molds and equipment becomes very high
Solution Approach 1:
The patent replaces expensive, durable injection molds with a disposable silicone rubber mold that can be easily fabricated. The silicone mold is used for a limited number of applications and then discarded, eliminating the need for costly metal molding equipment while achieving satisfactory adhesion results through the flexible nature of silicone rubber.
Solution Approach 2:
The patent changes the physical state and properties of the polymer material by using thermoplastic polymers that can be softened by heat and pressure. This allows the polymer to be applied in a softened state and then固化 upon cooling, achieving good adhesion without requiring expensive injection molding equipment. The process parameters (temperature, pressure, time) are carefully controlled to optimize adhesion.
2Manufacturing precision
If injection molding with high closing force is used, then the polymer material can be properly injected, but the operational flexibility is significantly reduced
Solution Approach 1:
The patent employs a heating element that can be electrically or otherwise heated to soften the polymer material. This thermal approach replaces the need for high closing force mechanical injection systems, providing operational flexibility while maintaining sufficient injection accuracy through controlled heating and manual or automated pressing.
3Reliability
If high-frequency welding is used to apply inserts, then the inserts adhere well along the outer perimeter, but inner portions may have incomplete adhesion creating air chambers
Solution Approach 1:
The patent removes the air chamber problem by using a flexible silicone rubber mold that conforms to the support surface. The silicone material's elasticity allows it to fill and eliminate air pockets between the polymer insert and the support, ensuring uniform adhesion across the entire surface including inner portions, not just the perimeter.
4Ease of manufacture
If silk-screen printing is used to apply polymer designs, then the process can be simplified, but the support surface must be perfectly flat to prevent blotching
Solution Approach 1:
The patent uses a flexible silicone rubber mold that can conform to non-flat support surfaces. The flexibility of the silicone material allows it to adapt to surface irregularities, eliminating the requirement for perfectly flat supports while maintaining process simplicity. The mold flexes to accommodate surface variations, preventing blotching and ensuring uniform polymer application.
5Shape
If silk-screen printing or injection molding is used, then designs can be applied, but the thickness is limited and they project minimally from the base
Solution Approach 1:
The patent applies excessive polymer material beyond the exact design boundaries during the molding process. The silicone mold allows the polymer to be over-applied and then trimmed back to the precise dimensions. This approach enables greater thickness control and prevents minimal projection, as the polymer can be applied in excess and then precisely finished to achieve the desired thickness without being constrained by traditional molding limits.
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 method enables efficient, cost-effective application of polymer inserts with high surface hardness, low abrasion, and high resilience, ensuring complete adhesion and aesthetic perfection, while being adaptable to various support materials and structures.
Implementation Method 1
pressing the cover (18) of the mould (10) onto the base (12) of the mould so as to: define the mould impression (16)
Implementation Method 2
perimetrally compress the support layer (30, 30a) by means of the closing edge (14) against one of the facing surfaces (13, 17) of the mould (10)
Implementation Method 3
allow adhesion of the polymer mixture M present inside the mould impression (16) to the support layer (30, 30a)
Data Source
AI summary
Method for applying an insert 40 of polymer material onto a support layer 30, 30a, comprising the following steps: providing a mould 10 comprising at least one base 12 and at least one cover 18; the base 12 and the cover 18 being suitable for defining with the facing surfaces 13, 17, when the mould 10 is closed, a mould impression 16 which is delimited perimetrally by a closing edge 14; spraying a polymer mixture M in the fluid state onto one of the two facing surfaces 13, 17 of the mould 10; introducing the support layer 30, 30a between base 12 and cover 18 of the mould 10 so that, when the mould 10 is closed, the support layer 30, 30a projects from the closing edge 14; pressing the cover 18 of the mould 10 onto the base 12; opening the mould 10 in order to remove the support layer 30, 30a and the associated insert 40; trimming the portion S of the polymer mixture M which, following the spraying and pressing steps, has flowed outside the external perimeter of the impression mould 16. Finally, the invention relates to a mould 10 which can be used to implement this method and the articles 20 which may be obtained by means of this method.