Double-Layer Plastic Molding on Soft Cloth for Stable 3D Ornaments
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Solution Overview
Problem
Existing methods for molding plastics on soft fabrics fail to provide sufficient stability due to the unstable shape and softness of the fabrics, leading to unstable molded plastics.
Innovation Solution
A two-step molding process involving a die feed-in method with pin-point feed-in points, where a first plastic layer is fused with the cloth to form a substrate, followed by a second layer being fused with the substrate to create a double-layer plastic product, with tailoring and trimming to ensure stability and alignment.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If ultrasonic finishing method is used to melt and assemble plastics on fabrics, then the plastics can be assembled on the fabrics, but the molded plastics lack sufficient stability due to the softness and unstable shape of the fabrics
Solution Approach 1:
The patent divides the molding process into two distinct stages: a first molding process that creates a substrate layer with enhanced stability, and a second molding process that forms the final graphical ornament on the substrate. This segmentation allows each stage to optimize for its specific function, with the first stage addressing stability and the second stage addressing the final aesthetic form.
Solution Approach 2:
The first molding process performs a preliminary action by creating a substrate layer before the final molding. This substrate layer is formed with a molecular structure that provides stability and serves as a foundation for the second molding process, allowing the final graphical ornament to be molded on a stable base rather than directly on unstable fabric.
2Reliability
If plastics are molded directly on soft fabrics, then the process is simple, but the molded plastics cannot maintain stability due to the unstable shape of the fabrics
Solution Approach 1:
The patent segments the molding process into two sequential steps: first creating a stable substrate layer through a preliminary molding process, then forming the final graphical ornament on this stable substrate. This segmentation resolves the contradiction by separating the stability-function from the aesthetic-form-function, allowing each to be optimized independently.
Solution Approach 2:
The first molding process performs a preliminary action of creating a stable substrate layer that serves as a foundation for the second molding process. This preliminary action establishes stability before the final aesthetic form is created, resolving the contradiction between simplicity and stability.
3Reliability
If a single-layer plastic molding is used, then the process is straightforward, but the product lacks both stability and aesthetic appeal
Solution Approach 1:
The patent segments the plastic structure into two layers: a first plastic layer forming a substrate with enhanced stability, and a second plastic layer forming the graphical ornament with aesthetic appeal. This segmentation allows each layer to fulfill its specific function, with the substrate providing stability and the graphical layer providing aesthetic value.
Solution Approach 2:
The patent creates a composite plastic structure with two layers having different functions. The first layer provides stability and structural support, while the second layer provides the graphical ornament and aesthetic appeal. This composite approach resolves the contradiction by combining materials and structures that fulfill both stability and aesthetic requirements.
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 method enhances the stability and soft texture of molded plastics, increasing the product's value and public appreciation by providing a stable and aesthetically pleasing three-dimensional graphical ornament.
Implementation Method 1
after hot melting, a plastic that is injected in is fused and set with the cloth
Implementation Method 2
a die feed-in is implemented on soft cloth, and after hot melting, a plastic that is injected in is fused and set with the cloth
Implementation Method 3
The plastic pattern that has been set is punched and trimmed, to form a base of a shaped product
Implementation Method 4
after hot melting, the plastic that is injected in is fused and set with a surface of the base to form the needed shape
Data Source
AI summary
A production method for molding includes a. a first molding: depending on a shape to be molded, implementing a die feed-in on soft cloth, with the plastic that is injected in being fused and set with the cloth, for serving as a substrate layer; b. punching and trimming: punching and trimming the plastic that has been set to form a base; c. a second molding: implementing a second die feed-in on the base of a shaped product, with the injected-in plastic being fused and set with a surface of the base, to form the needed shape; d. tailoring and trimming: tailoring and trimming an edge interface between two layers of the assembled plastic to form a shaped product of a double-layer plastic on the soft cloth.