Resin Molded Article Cover Layer Rigidity via Coating
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Solution Overview
Problem
Resin molded articles with thin cover layers are prone to bending or distortion during the curing process of the ultraviolet curable resin, leading to potential detachment from the resin base material layer and an aesthetically undesirable appearance.
Innovation Solution
A resin molded article design featuring a cover layer made from a polymer membrane with a first and second coating layer applied to its end surfaces, providing rigidity and preventing distortion during curing, while maintaining the cover layer's flatness and adhesion to the resin base material layer.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Volume of moving object
If the thickness of the cover layer is reduced to minimize article bulk, then the article becomes more portable, but the cover layer becomes prone to bending and distortion during resin curing
Solution Approach 1:
The patent applies composite materials by combining the thin polymer membrane cover layer with coating layers having different physical properties. The coating layers are applied to at least one surface of the cover layer to form a composite structure that maintains the thin overall profile while providing the necessary rigidity and dimensional stability during UV curing, preventing bending and distortion without increasing bulk thickness
Solution Approach 2:
The patent changes the physical parameters of the cover layer system by applying coating layers that alter the surface energy, rigidity, and thermal expansion characteristics. These parameter changes in the coating layers compensate for the inherent flexibility of the thin polymer membrane, maintaining flatness during the exothermic UV curing process without requiring increased thickness
2Volume of moving object
If the cover layer is made thinner to reduce article thickness, then portability improves, but adhesion to the resin base material layer deteriorates during curing
Solution Approach 1:
The patent uses composite material structure where coating layers are applied to the polymer membrane cover layer. These coating layers serve as intermediate bonding layers that enhance adhesion between the thin cover layer and the resin base material layer during UV curing, preventing detachment while maintaining the reduced thickness profile
Solution Approach 2:
The patent applies local quality by treating the surface of the polymer membrane with coating layers specifically at the interface regions where adhesion is critical. The coating layers are applied to at least one surface of the cover layer, creating localized zones of enhanced bonding strength at the resin-cover layer interface without affecting the overall thinness of the cover layer
3Volume of moving object
If the cover layer thickness is minimized for aesthetic purposes, then the design appearance is improved, but bending during curing becomes more severe
Solution Approach 1:
The patent employs composite materials by combining the thin polymer membrane with coating layers that provide structural support. This composite structure allows the cover layer to maintain minimal thickness for aesthetic appeal while the coating layers prevent bending and distortion during UV curing, preserving the flat, smooth appearance
Solution Approach 2:
The patent applies beforehand cushioning by pre-applying coating layers to the cover layer before the UV curing process begins. These coating layers act as a protective cushion that resists bending forces generated during the exothermic curing of the resin base material layer, maintaining the cover layer's flat shape throughout the manufacturing 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
The solution effectively suppresses bending and strain in the cover layer, ensuring it remains flat and securely attached to the resin base material layer, enhancing the aesthetic appeal and durability of the resin molded article.
Implementation Method 1
a resin base material layer made from an ultraviolet curable resin
Data Source
AI summary
A resin molded article is equipped with a resin base material layer, a cover layer, and a design layer. The design layer is provided on a design side end surface of the resin base material layer, whereas the cover layer is provided on a cover side end surface which is a rear surface of the design side end surface. Further, the cover layer includes a first end surface facing toward the cover side end surface, and a second end surface which is a rear surface of the first end surface. The first end surface is covered by a first coating layer, and the second end surface is covered by a second coating layer.