Resin Molding Mold Mirror-Surface Coat Layer
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Solution Overview
Problem
Existing resin molding molds require multiple complex processes for embossing, including adjustments of concavo-convex intervals and blasting, which are difficult to uniformly apply across the entire surface, making it challenging to achieve high luster and quality texture on resin molded products.
Innovation Solution
A resin molding mold with a mirror-surface coat layer formed using a thermosetting resin with thermal conductivity between 0.10 W/(mK) and 0.99 W/(mK), having a thickness of 1.0 μm to 30 μm, and featuring a flat-surface maintaining part to ensure a stable, scratch-resistant, and glossy surface.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If multiple blasting processes are applied to achieve high luster and quality texture, then the surface quality of resin molded products is improved, but the manufacturing complexity and number of processes increase significantly
Solution Approach 1:
The patent combines multiple blasting processes into a single integrated coating layer application. The mirror-surface coat layer incorporates the functions of multiple sequential blasting operations (concavo-convex formation, intermediate blasting, and final finishing) into one coating step, thereby reducing the total number of processes while maintaining surface quality improvements.
Solution Approach 2:
The mirror-surface coat layer is formed as a composite structure with specific thermal conductivity properties (0.10 W/(mK) to 0.99 W/(mK)). This composite coating integrates multiple functional properties (surface texture, thermal management, and gloss generation) into a single material layer, eliminating the need for multiple separate blasting processes.
2Ease of manufacture
If concavo-convex intervals are adjusted to 0.3 to 0.5 mm for easy blasting material placement, then the blasting process becomes easier, but the uniformity of the embossing pattern is reduced
Solution Approach 1:
The patent changes the critical parameter from concavo-convex interval spacing to coating layer thermal conductivity and thickness. By controlling the thermal conductivity (0.10 W/(mK) to 0.99 W/(mK)) and thickness (1.0 μm to 30 μm) of the mirror-surface coat layer, the invention achieves uniform surface quality without relying on specific concavo-convex intervals, thereby maintaining both ease of manufacture and manufacturing precision.
3Manufacturing precision
If a thick mirror-surface coat layer is applied to ensure complete coverage and gloss, then the surface coverage is improved, but the risk of surface disturbances and liquid dripping increases
Solution Approach 1:
The patent optimizes the thickness parameter of the mirror-surface coat layer to a specific range (1.0 μm to 30 μm). This parameter optimization ensures sufficient surface coverage and gloss while preventing excessive thickness that would cause surface disturbances and liquid dripping, thereby maintaining both surface coverage and surface stability.
4Use of energy by moving object
If the thermal conductivity of the mirror-surface coat layer is increased to improve heat dissipation, then the cooling efficiency is improved, but the gloss generation capability is reduced
Solution Approach 1:
The patent defines an optimal thermal conductivity range (0.10 W/(mK) to 0.99 W/(mK)) for the mirror-surface coat layer. This parameter range balances heat dissipation efficiency and gloss generation capability, allowing the coating to provide adequate thermal management while maintaining the optical properties necessary for high-gloss surfaces.
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 allows for easy generation of gloss and improved texture on resin molded products by preventing scratches, disturbances, and liquid dripping, while maintaining a stable surface state, thus enhancing the quality and durability of the molded products.
Implementation Method 1
a mirror-surface coat layer formed by using a thermosetting resin having a thermal conductivity in a range from 0.10 W/(mK) or more to 0.99 W/(mK) or less
Data Source
AI summary
A resin molding mold in accordance with the present application is a resin molding mold for molding a resin molded product. The resin molding mold includes a molding mold and a mirror-surface coat layer formed on a mold surface of the molding mold. The mirror-surface coat layer is formed by a thermosetting resin having a thermal conductivity in a range from 0.10 W/(mK) or more to 0.99 W/(mK) or less. The thickness of the mirror-surface coat layer is set in a range from 1.0 μm or more to 30 μm or less, and is preferably set to 20 μm or less. The surface of the mirror-surface coat layer is provided with a flat-surface maintaining part formed into a substantially flat surface.