Simultaneous Molding and Decorating with Segmented Design Sheets
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Solution Overview
Problem
Conventional simultaneous injection-molding and decorating methods are limited in size, preventing the decoration of large-sized objects such as television panels with lateral widths exceeding the cylinder circumference of printing machines, as they cannot accommodate lengths larger than the outer circumference of the printing machine cylinder.
Innovation Solution
The method involves positioning every other design on the decorating sheet at a constant interval within the metal mold cavity and using sensors to detect feeding direction marks for precise alignment, allowing for the decoration of long objects with lengths beyond the printing machine's cylinder circumference using existing equipment.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Area of stationary object
If the cylinder outer circumference of the gravure printing machine is increased to accommodate larger decoration sizes, then the maximum decoration size increases, but the equipment cost and complexity increase significantly
Solution Approach 1:
The decorating sheet is divided into multiple sections corresponding to different cylinder revolutions. By selecting every other design at constant intervals, the system effectively segments the decoration pattern to fit within the existing cylinder circumference while achieving the appearance of larger size coverage through strategic positioning and spacing of design elements.
2Area of stationary object
If every other design is positioned at constant intervals on the decorating sheet, then long objects can be decorated using existing equipment, but the positioning precision and alignment requirements increase
Solution Approach 1:
The system incorporates sensors to detect feeding direction marks on the decorating sheet, providing feedback for precise positioning. This feedback mechanism enables accurate alignment of every other design at constant intervals, ensuring proper positioning even when covering lengths beyond the cylinder circumference using existing equipment.
Data Source
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Figure 3(a)~3(b)
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AI summary
In the simultaneous molding and decorating method for forming an image onto the surface of a resin molding simultaneously with resin molding by holding a decoration sheet on which the image is rotary printed in a die, such a decoration sheet as having a predetermined pattern for every revolution of the cylinder of a printing machine wherein the image is formed in the longitudinal direction at a constant interval is used. By holding the decoration sheet longer than one revolution but shorter than two revolutions of that in the die and performing resin molding, the image is formed onto the surface of a long molding exceeding the outer circumference of the cylinder.