Sheet Laminate Partial Heating to Prevent Adhesive Peeling
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Solution Overview
Problem
The existing heat stamping method for manufacturing sheet laminates often results in the adhesive part and protective sheet peeling away during molding, leading to quality issues with the bent sheet laminate.
Innovation Solution
A method involving a bending step where the sheet laminate is partially heated after bending, specifically targeting the connecting surface to relieve distortion and prevent peeling, while using a mold with a heating part to contact the connecting surface and insulate the flat and side surfaces to maintain shape during heating.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Shape
If heat stamping is performed on a sheet laminate with adhesive part and protective sheet, then the sheet can be bent and shaped, but the adhesive part, liner, and protective sheet peel away during molding
Solution Approach 1:
The patent applies preliminary action by performing partial heating on the connecting surface after the bending step but before final assembly. This preliminary heat treatment removes distortion in the adhesive part before it can cause peeling during subsequent handling or assembly, thus preventing the peeling problem while maintaining the bent shape.
Solution Approach 2:
The patent changes the temperature parameter locally by applying heat specifically to the connecting surface where distortion occurs. This localized parameter change (heating the connecting surface to a specific temperature range) relieves internal stress and distortion without affecting the entire sheet laminate, thereby preventing adhesive peeling while preserving the overall shape.
2Reliability
If the entire sheet laminate is heated to remove distortion, then adhesive part peeling is prevented, but the design surface and adhesive properties are compromised
Solution Approach 1:
The patent applies local quality by heating only the connecting surface (the specific area where distortion occurs) rather than the entire sheet laminate. This localized heating approach removes distortion in the critical area while preserving the quality of the design surface and adhesive properties in other areas, thus resolving the contradiction between preventing peeling and maintaining overall quality.
Solution Approach 2:
The patent segments the heating process by dividing the sheet laminate into different zones: the connecting surface that requires heating to remove distortion, and the design surface and adhesive areas that should not be heated to preserve their properties. This segmentation allows selective heat treatment that addresses the peeling problem without compromising overall quality.
3Ease of manufacture
If conventional heat stamping is used, then manufacturing process is simple, but adhesive part and protective sheet peel away during molding
Solution Approach 1:
The patent maintains the simplicity of the conventional heat stamping process by adding a preliminary partial heating step that targets only the connecting surface. This additional step is straightforward to implement and does not significantly complicate the manufacturing process, while effectively preventing adhesive peeling during molding.
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 approach effectively prevents adhesive part peeling and ensures a high-quality sheet laminate by annealing the connecting surface, maintaining the integrity of the laminate's design and functionality.
Implementation Method 1
distortion in said part can be removed by performing a partial annealing process through partial heating of the connecting surface
Implementation Method 2
a heating part that makes contact with the connecting surface and heats the connecting surface
Implementation Method 3
an insulating part that insulates the flat surface part and the side surface, and that makes contact with the flat surface part and the side surface
Data Source
AI summary
A method for manufacturing a sheet laminate to be affixed to an adherent surface of an object, the method comprising preparing a sheet member having a front surface to become a design surface and a rear surface on which an adhesive part has been formed, bending an edge part of the sheet member by sandwiching the sheet member from a front surface side and a rear surface side in a mold, and heating a part of a bent sheet member. The sheet laminate has a flat part spreading out in a flat plate shape, a side surface on which the edge part bent by the bending step is configured, and a connecting surface protruding and curving toward the front surface side between the flat part and the side surface, and in the heating step, the connecting surface is partially heated after the side surface is molded in the bending step.