Rotational Sintering Mold Color Application
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Solution Overview
Problem
Existing methods for producing multicolored plastic molded skins for motor vehicles are inefficient due to high equipment requirements, risk of leakage, blurring of color boundaries, and inability to effectively apply lettering or graphic representations, especially with rotational sintering techniques.
Innovation Solution
Combining rotational sintering with pad printing to apply a color medium like dispersion paint, lacquer, or liquid PVC to the mold surface, where the image is transferred as a positive representation onto the plastic skin, ensuring clear contours and irreversible color binding.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If mask technique is used to produce multicolored plastic molded skins, then color separation is achieved, but equipment complexity and sealing requirements increase significantly
Solution Approach 1:
The patent removes the complex mask system entirely and extracts only the essential function of color separation. Instead of using physical masks with sealing mechanisms, the invention applies color media directly to the mold surface in the desired pattern, eliminating the need for masks, sealing systems, and associated complexity while maintaining color separation precision.
Solution Approach 2:
The color media are applied to the mold surface before the plastic powder is introduced and melted. This preliminary application of color in the desired pattern eliminates the need for complex masking during the molding process, as the color is already in position to be transferred to the plastic skin.
2Manufacturing precision
If masks with sealing mechanisms are used, then color boundaries are clearly defined, but risk of leakage and blurring increases
Solution Approach 1:
The patent eliminates the mask sealing system entirely, removing the source of leakage problems. Color boundaries are defined by the precise application pattern of the color media on the mold surface rather than by physical barriers, thereby eliminating leakage risk while maintaining clear color boundaries.
3Manufacturing precision
If rotational sintering with multiple powder containers is used, then multicolored molded skins are produced, but production time and process complexity increase
Solution Approach 1:
The patent combines multiple color applications into a single molding cycle. Instead of sequentially processing different colored powders in separate steps, the color media are pre-applied to the mold surface in the desired multicolored pattern, and all colors are transferred to the plastic skin simultaneously in one sintering operation, significantly improving production efficiency.
Solution Approach 2:
The color media are applied to the mold surface before the plastic powder is introduced. This preliminary color application allows all color patterns to be established in advance, so that during the single molding cycle, the plastic powder simply picks up the pre-positioned colors, eliminating the need for multiple sequential powder application steps.
4Manufacturing precision
If complex masking systems are integrated into powder containers, then color separation is maintained, but space requirements and cable/hose packaging increase
Solution Approach 1:
The patent removes the integrated mask system from the powder container, eliminating the need for cables, hoses, and sealing mechanisms. Color separation is achieved through direct application of color media to the mold surface rather than through complex container-integrated masking systems, thereby reducing space requirements and eliminating cable/hose packaging.
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 allows for cost-effective production of multicolored, graphically designed slush skins with clear images and graphics on motor vehicle components without the need for complex masking or additional technical outlay, ensuring durable color integration and preventing color smearing.
Implementation Method 1
the plastic powder being melted on the surface of the heated mold
Implementation Method 2
The color is absorbed by the plastic when it melts and is irreversibly bound in the plastic
Implementation Method 3
The solvent from the color medium is evaporated on the hot tool surface and the color remains in the form of pigments on the tool surface
Data Source
Figure 1
AI summary
The method involves heating a rotation sinter tool, and melting plastic powder at the tool surface. A molded skin is formed on the tool surface, and the tool is cooled. The plastic molded skin is removed. A colored surface or a negative representation of a printed image is generated, before the melting of the plastic powder in the heated rotation sinter tool by coating a color medium on the tool surface. The colored medium is made of emulsion paint, paint or liquid polyvinyl chloride.