Textile Resin Composite Molded Pattern Definition

Solution Overview

Problem

Current methods for producing textile/thermoplastic resin composite parts fail to achieve high-definition patterns with both positive and negative etchings, limited depth, and geometric variability, and do not allow for impressions on etched patterns.

Innovation Solution

A method involving a mold-based process where a thermoplastic resin composition is applied, heated, and then a textile is applied to it, allowing for the creation of composite parts with varied geometry and depth, including the application of a colored composition for impressions.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Manufacturing precision

If conventional coating and embossing methods are used, then the process is simple and easy to manufacture, but the pattern definition is limited and cannot achieve high-definition positive and negative etchings simultaneously

Engineering Contradiction:

Improvepattern definitionVSAvoidprocess complexity

Core Design Contradiction:

Manufacturing precisionVSDevice complexity

Solution Approach 1:

The mold is prepared in advance with pre-formed positive and negative relief patterns before the thermoplastic resin is applied. This preliminary molding of the pattern structure allows the textile composite to receive high-definition patterns directly during the coating process, eliminating the need for subsequent separate embossing operations and achieving both positive and negative etchings simultaneously.

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

A mold acts as an intermediary tool that transfers the desired pattern geometry to the thermoplastic resin and subsequently to the textile composite. The mold contains the precise positive and negative relief structures that define the pattern, serving as a mediator between the design intent and the final product, enabling high-definition patterns without complex post-processing.

Inventive Principle:

Principle #24Intermediary (Mediator)

2Manufacturing precision

If conventional embossing methods are used, then the manufacturing process is simple, but the etching depth is insufficient and geometric variability is limited

Engineering Contradiction:

Improveetching depthVSAvoidmanufacturing simplicity

Core Design Contradiction:

Manufacturing precisionVSEase of manufacture

Solution Approach 1:

The mold is prepared in advance with pre-formed positive and negative relief patterns before the thermoplastic resin is applied. This preliminary molding of the pattern structure allows the textile composite to receive high-definition patterns directly during the coating process, eliminating the need for subsequent separate embossing operations and achieving both positive and negative etchings simultaneously.

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

The thermoplastic resin is heated to specific temperature ranges (70-300°C, preferably 100-260°C) to control its viscosity and flow characteristics during application. This parameter control allows the resin to properly fill the mold cavities and adhere to the textile, enabling deep etching patterns while maintaining manufacturing simplicity through controlled thermal processing.

Inventive Principle:

Principle #35Parameter changes

3Adaptability or versatility

If conventional methods are used, then the production process is straightforward, but it is not possible to place impressions on etched patterns

Engineering Contradiction:

Improvepattern versatilityVSAvoidprocess steps

Core Design Contradiction:

Adaptability or versatilityVSDevice complexity

Solution Approach 1:

The application of colored composition and the formation of relief patterns are merged into a single integrated process step. The colored composition is applied to the heated thermoplastic resin in the mold simultaneously with the pattern formation, allowing impressions to be placed on etched patterns in one operation rather than requiring separate coloring and embossing steps.

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The mold is prepared in advance with pre-formed positive and negative relief patterns before the thermoplastic resin is applied. This preliminary molding of the pattern structure allows the textile composite to receive high-definition patterns directly during the coating process, eliminating the need for subsequent separate embossing operations and achieving both positive and negative etchings simultaneously.

Inventive Principle:

Principle #10Preliminary action

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

Enables the production of composite parts with high-definition, variable geometry, and deep patterns, including both positive and negative reliefs, and allows for impressions on the etched patterns, enhancing the aesthetic and functional capabilities of the materials.

Implementation Method 1

heating to gelation of the composition (A), i.e. heating to reach a mold temperature of between 70 and 300° C., preferably between 100 and 260° C.

Methodology Applied

Scientific EffectGelation: Gel

Implementation Method 2

Cool the mold

Methodology Applied

Scientific EffectCooling: Cooling

Data Source

PatentUS11752706B2Method for preparing a textile/resin composite part

Publication Date: 2023.09.12 IVY GRP HLDG

AI summary

The present invention relates to a method for manufacturing a textile/thermoplastic resin composite part, comprising the following steps: (a) providing a mould; (b) applying at least one composition (A) comprising at least one thermoplastic resin; (c) heating the mould; (d) applying the textile to the heated thermoplastic resin; (e) cooling the mould; (f) unmoulding.