3D Resin Decoration Flat Rear Surface via Indented Mold

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Solution Overview

Problem

Existing methods for manufacturing three-dimensional decoration pieces of synthetic resin, such as those for automobiles and bicycles, face challenges including non-flat rear surfaces, difficulty in cutting, limited bonding strength, and requirements for extensible base materials due to the use of protruding and indented molds, which restrict material choices and manufacturing accuracy.

Innovation Solution

A method involving laying thermoplastic synthetic resin layers on a flat cathode and using an indented mold for high-frequency dielectric heating to form three-dimensional pieces with flat rear surfaces, allowing for easy cutting and bonding, and enabling the use of non-extensible base materials by avoiding the need for protruding molds and precise dimensional accuracy.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Shape

If both protruding mold and indented mold are used to manufacture three-dimensional decoration piece, then the three-dimensional pattern is molded inside fusion cutter, but the rear surface becomes non-flat with recess, reducing bonding area and strength

Engineering Contradiction:

Improvethree-dimensional patternVSAvoidbonding area

Core Design Contradiction:

ShapeVSArea of stationary object

Solution Approach 1:

The patent removes the protruding mold from the manufacturing process, using only the indented mold. This extraction eliminates the recess formation on the rear surface, providing a flat bonding area while still achieving the three-dimensional pattern through the indented mold's cavity design

Inventive Principle:

Principle #2Taking out (Extraction)

Solution Approach 2:

Instead of using both protruding and indented molds to create the three-dimensional pattern, the patent inverts the approach by using only the indented mold in reverse fashion - the indented mold's cavity directly forms the three-dimensional protrusion on the decoration piece without needing a corresponding protruding mold

Inventive Principle:

Principle #13The other way round (Inversion)

2Manufacturing precision

If protruding mold and indented mold are used with high dimensional accuracy, then three-dimensional pattern is formed, but the base member must be extensible, limiting material choices

Engineering Contradiction:

Improvedimensional accuracyVSAvoidbase member material selection

Core Design Contradiction:

Manufacturing precisionVSAdaptability or versatility

Solution Approach 1:

The patent removes the protruding mold that caused the base member to be stretched between molds. By using only the indented mold, the base member is no longer required to be extensible, allowing use of non-extensible materials like leather and rigid fabrics

Inventive Principle:

Principle #2Taking out (Extraction)

Solution Approach 2:

The patent changes the molding parameter from requiring base member extensibility to working with non-extensible materials by eliminating the protruding mold constraint, thereby expanding the range of usable base member materials

Inventive Principle:

Principle #35Parameter changes

3Strength

If thermoplastic synthetic resin material is welded to base member at unnecessary parts, then bonding is achieved, but cutting and removing unnecessary parts becomes difficult

Engineering Contradiction:

Improvebonding strengthVSAvoidcutting ease

Core Design Contradiction:

StrengthVSEase of manufacture

Solution Approach 1:

The patent applies local quality by creating a flat rear surface with a designated bonding area rather than welding across the entire surface. This localized bonding approach maintains strength while enabling easy cutting and removal of non-bonding areas

Inventive Principle:

Principle #3Local quality

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 method enables reliable bonding, reduces manufacturing costs, and allows for the use of a wide range of base materials, improving the cutting process and bonding strength of the three-dimensional decoration pieces.

Implementation Method 1

pressing the layer materials from above by an indented mold operating as anode, to melt and mold the materials by high frequency dielectric heating

Methodology Applied

Scientific EffectHigh frequency dielectric heating: Dielectric Heating

Data Source

PatentUS8110059B2Three-dimensional decoration piece made of synthetic resin and method of manufacturing the same

Publication Date: 2012.02.07 NOBUO KURODA

AI summary

There are provided (1) a method of manufacturing a three-dimensional decoration piece having a flat rear surface, (2) a method of manufacturing the decoration piece by easily cutting the same by means of a fusion cutter, (3) a method of manufacturing the decoration piece having a bonding or sticking feature on the rear surface and (4) a method of manufacturing a three-dimensional decoration piece without limiting the characteristics of the base member thereof.The three-dimensional decoration piece is manufactured by using an indented mold and high frequency dielectric heating. An indented mold having a second fusion cutter and arranged along an outer periphery of the fusion cutter is used. Firstly, a three-dimensional molded body of upper and intermediate layers having a recessed section on a lower surface thereof is molded by means of an indented mold and a protruding mold, and subsequently a lower layer material is molten by high frequency dielectric heating and made to flow into the recessed section. Firstly, a three-dimensional molded body of upper and intermediate layers is molded, and subsequently the three-dimensional molded body is welded to a base member by means of high frequency dielectric heating.