Resin Molded Body Anchor Structuring Layer Adhesion
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Solution Overview
Problem
Resin molded bodies with metallic luster lack sufficient strength and adhesiveness to withstand large forces and maintain decorative finishes.
Innovation Solution
A resin molded body composed of fiber-reinforced resin with an anchor structuring layer where reinforcing fibers bite into a welding layer, enhancing adhesion and strength, and featuring a decorative sheet with a metallic luster layer, transparent protective layer, and welding layer.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Illumination intensity
If a sheet having a metallic luster is placed in an injection mold and is integrally molded with a resin, then the resin molded body exhibits metallic luster, but the resin molded body lacks sufficient strength and sheet adhesiveness to withstand large forces
Solution Approach 1:
The invention uses fiber-reinforced resin as the base material instead of ordinary resin, creating a composite structure that combines the aesthetic properties of the metallic luster sheet with the mechanical strength of reinforcing fibers. This resolves the contradiction by making the resin matrix itself stronger through fiber reinforcement.
Solution Approach 2:
The invention introduces an anchor structuring layer with an uneven surface profile at the boundary between the welding layer and the body. This curved/uneven interface increases the bonding area and mechanical interlocking, allowing the decorative sheet to withstand large forces while maintaining metallic luster appearance.
2Ease of manufacture
If ordinary resin is used for the body, then the manufacturing process is simple, but the resin molded body cannot withstand large forces
Solution Approach 1:
The invention replaces ordinary resin with fiber-reinforced resin, creating a composite material that maintains ease of injection molding while dramatically improving force resistance. The fibers are embedded in the resin matrix during the molding process, providing structural strength without complicating the manufacturing workflow.
3Ease of manufacture
If the boundary between the welding layer and the body is flat, then the manufacturing process is simple, but the adhesion between the decorative sheet and the body is insufficient
Solution Approach 1:
The invention introduces an anchor structuring layer with an uneven surface profile at the boundary between the welding layer and the body. This curved/uneven interface increases the bonding area and mechanical interlocking, allowing the decorative sheet to withstand large forces while maintaining metallic luster appearance.
Solution Approach 2:
The invention applies the anchor structuring layer specifically at the boundary region between the welding layer and the body, rather than throughout the entire structure. This localized modification provides enhanced adhesion where it is most needed at the interface, while keeping the rest of the structure simple and easy to manufacture.
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 provides high strength and adhesion, allowing the resin molded body to withstand large forces while maintaining metallic luster, making it a suitable alternative to metal articles for structural members like bicycle components, reducing weight while preserving aesthetic appeal.
Implementation Method 1
an anchor structuring layer configured at boundary between the welding layer and the body, and having an uneven shape such that the reinforcing fibers of the body bite into the welding layer
Data Source
AI summary
A resin molded body includes a body having a surface, and a decorative sheet adhered to the surface of the body. The decorative sheet has a metallic luster layer, a transparent protective layer positioned on an outer side of the metallic luster layer, and a welding layer adhered to the surface of the body. The body is formed from a fiber-reinforced resin having reinforcing fibers defining an anchor structuring layer such that the reinforcing fibers of the body bite into the welding layer at a boundary portion between the welding layer and the body such that the boundary portion has an uneven shape.