Resin Molding Mold Buffer Layer Gloss Control
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Solution Overview
Problem
Resin molded products with embossing often suffer from uneven gloss reduction and 'white blurring' due to irregularities in the molding process, particularly when sandblasting is used, leading to scratches and a defective appearance.
Innovation Solution
A resin molding mold with a buffer layer composed of a thermosetting resin and fine particles of spherical shape, with specific gravity between 0.4 g/ml and 0.9 g/ml, is used to create a surface with spherical concave portions, preventing steep ridges and galling, and reducing gloss through diffused light reflection.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Illumination intensity
If sandblasting is used to roughen the mold surface to reduce gloss, then the gloss value is reduced, but irregularities and steep ridges occur on the mold surface causing scratches and galling
Solution Approach 1:
The patent introduces a buffer layer as an intermediary substance between the mold surface and the resin molded product. This buffer layer contains fine particles (1-15 μm) dispersed in a thermosetting resin, which gently roughen the surface to reduce gloss without creating the steep ridges and irregularities caused by direct sandblasting. The buffer layer mediates the interaction between the mold and product, preventing galling and scratches while achieving the desired gloss reduction.
Solution Approach 2:
The patent changes the parameters of surface roughening by controlling the particle size (1-15 μm), particle shape (substantially spherical), and bulk specific gravity (0.4-0.9 g/ml) of the fine particles in the buffer layer. These parameter changes ensure that the particles can reduce gloss through diffused light reflection without being large enough to create harmful irregularities or steep ridges on the mold surface.
2Illumination intensity
If the mold surface is roughened to prevent window reflection, then gloss is reduced, but white blurring occurs on the embossed surface
Solution Approach 1:
The patent precisely controls the particle size parameters (1-15 μm) and bulk specific gravity (0.4-0.9 g/ml) of the fine particles to achieve optimal light scattering. This parameter optimization allows the buffer layer to reduce gloss through diffused reflection while maintaining accurate embossing transfer, preventing the white blurring that occurs when particles are too large or irregularly shaped.
Solution Approach 2:
The buffer layer is formed as a composite material combining fine particles with a thermosetting resin matrix. This composite structure allows the particles to provide light-scattering gloss reduction while the resin provides a smooth, uniform medium that ensures accurate transfer of embossing patterns without white blurring.
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 prevents scratches and white blurring, achieving a stable reduction in gloss without additional coating processes, while maintaining the embossing pattern's integrity.
Implementation Method 1
reducing gloss through diffused light reflection
Implementation Method 2
a buffer layer formed on a mold surface of the molding mold, and the buffer layer is formed by a mixture of a thermosetting resin and fine particles
Data Source
AI summary
To provide a resin molding mold capable of forming a resin molded product having embossing in which by controlling appearance of gloss, its texture is improved, and the resin molded product is prevented from occurrence of white blurring on the surface on which the molded embossing is formed.A resin molding mold in accordance with the present application is used for molding a resin molded product having embossing formed thereon. The resin molding mold includes a molding mold and a buffer layer formed on an inside mold surface of the molding mold. The buffer layer is formed by a mixture of a thermosetting resin and fine particles having substantially spherical shapes. The fine particles have a bulk specific gravity in a range from 0.4 g/ml or more to 0.9 g/ml or less, and on the surface of the buffer layer, a plurality of gloss adjusting convex portions having substantially spherical shapes derived from the fine particles are formed.