Textile-like In-mold Sheet Barrier Layer Design
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Solution Overview
Problem
The molding of textile-like resin molded bodies often results in a hard resin-like texture for the textile layer, creasing, pattern distortion, and thermal degradation due to direct contact with molten resin, which compromises the fiber texture and appearance.
Innovation Solution
A textile-like in-mold sheet is developed with a fiber sheet layer, adhesive layers, and a textile material layer, where the fiber sheet layer acts as a barrier to prevent resin permeation, and a surface protection layer is used to maintain the textile's texture and appearance during molding.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If molten resin is directly injected into the textile material during molding, then the textile material is bonded to the resin molded body, but the resin permeates into the textile layer causing it to harden and lose its fiber texture
Solution Approach 1:
The textile material is divided into multiple layers: a textile material layer (first layer) that maintains fiber texture, a porous layer (second layer) that allows controlled resin permeation for bonding, and optionally a base material layer (third layer) for structural support. This segmentation allows different regions to serve different functions - the first layer preserves appearance while the second layer enables bonding.
Solution Approach 2:
Different regions of the textile material structure are given different properties: the first layer has low porosity to prevent resin penetration and maintain texture, while the second layer has high porosity to allow resin permeation and achieve bonding. This local differentiation of material properties resolves the contradiction between bonding strength and texture preservation.
2Strength
If molten resin permeates into the textile material during cooling and solidifying, then bonding is achieved, but creasing and pattern distortion occur on the textile material
Solution Approach 1:
The textile material is segmented into a first layer for pattern preservation and a second porous layer for bonding. The porous layer acts as a buffer that absorbs resin and accommodates dimensional changes during cooling, preventing stress transmission to the patterned first layer.
Solution Approach 2:
The porous layer serves as an intermediary between the molten resin and the patterned textile material. It controls resin flow and absorbs expansion stresses, preventing direct transmission of mechanical stresses that would cause creasing and pattern distortion in the first layer.
3Strength
If textile material is in direct contact with molten resin during molding, then bonding is achieved, but thermal degradation of the textile material occurs
Solution Approach 1:
The porous layer acts as a thermal barrier and intermediary between the molten resin and the textile material layer. It controls the rate and extent of heat transfer, preventing excessive thermal energy from reaching and degrading the textile fibers while still allowing sufficient resin permeation for bonding.
Solution Approach 2:
The porous layer is strategically positioned between the hot resin and the temperature-sensitive textile material. Its high porosity allows resin flow while its physical structure provides thermal protection, creating a localized protective zone that preserves textile integrity during the high-temperature molding process.
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 allows for a textile-like resin molded body with an excellent texture and appearance, preventing resin embedding, creasing, and thermal degradation, while maintaining the three-dimensional structure and adhesion of the textile material.
Implementation Method 1
a first adhesive layer, and a textile material layer, in this order from the first surface toward the second surface
Implementation Method 2
the fiber sheet layer acts as a barrier to prevent resin permeation
Implementation Method 3
a molten resin is pressure-injected into the cavity
Implementation Method 4
the resin has solidified in a state in which the resin has permeated to the surface of the textile layer
Data Source
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AI summary
Disclosed is a textile-like in-mold sheet that is to be integrated with a resin molded body molded by injection of a molten resin by in-molding. The textile-like in-mold sheet includes at least a fiber sheet layer, a first adhesive layer, and a textile material layer, in this order from a surface that will serve as a side to be integrated with the resin molded body. Alternatively, the textile-like in-mold sheet includes at least a textile material layer and a temporary surface protection layer temporarily bonded to the textile material layer, in this order from the surface to be integrated with the resin molded body.