Thermoplastic Laminate Coating Layer for High-Temperature Mold Release
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Solution Overview
Problem
Existing methods face issues with coating layer floating during mold release, requiring cooling to 60°C or lower, which prolongs the molding cycle.
Innovation Solution
A layered sheet structure with specific resin components and a coating layer having a storage modulus of 3.00 × 10^6 Pa to 1.00 × 10^8 Pa at 150°C allows mold release without cooling to 60°C, using thermoplastic resins like polypropylene for strands and coating layers, and adhesion layers to enhance integration.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If a multi-layer structure with a barrier layer is used to prevent resin penetration and improve appearance, then the quality and appearance of the molded article are improved, but the manufacturing complexity and number of steps increase
Solution Approach 1:
The laminate is divided into multiple functional layers including a base layer, barrier layer, and transparent layer, each serving specific purposes. The barrier layer is further segmented into multiple sub-layers with different resin compositions to prevent penetration while maintaining appearance quality.
Solution Approach 2:
The patent uses composite materials by combining different resin types (cyclic olefin copolymer, styrene resin, acrylic resin) in a multi-layer structure. Each layer has specific properties that complement others, creating a composite laminate that prevents resin penetration while maintaining optical clarity and structural integrity.
2Manufacturing precision
If the number of molding steps is increased to achieve high-quality laminated structures, then the manufacturing precision is improved, but the productivity decreases
Solution Approach 1:
Multiple laminate layers are combined in a single co-molding step rather than assembling pre-formed layers separately. The support member with recesses allows simultaneous molding of multiple layers with different resins, achieving high-quality laminated structures while maintaining productivity.
Solution Approach 2:
The support member with pre-formed recesses is prepared beforehand to facilitate the co-molding process. The recesses are designed in advance to accommodate different resin materials and control their flow during molding, enabling complex multi-layer structures to be formed in one step.
3Reliability
If different resin materials are used for each layer to prevent penetration, then the reliability is improved, but the device complexity increases
Solution Approach 1:
Different resin materials are assigned to specific layers based on their functional requirements. The barrier layer uses resin compositions specifically selected to prevent penetration, while other layers use resins optimized for clarity, flexibility, or structural support, creating local quality variations that enhance overall reliability.
Solution Approach 2:
The patent varies physical and chemical parameters of resin materials across different layers, including molecular weight, composition ratios, and curing characteristics. These parameter changes enable each layer to perform its specific function while maintaining compatibility with adjacent layers in the co-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
Enables efficient mold release and subsequent molding without waiting for cooling, reducing the molding cycle time and maintaining product shape.
Implementation Method 1
a cyclic olefin copolymer resin and a styrene resin are immiscible with each other
Implementation Method 2
a support member having a plurality of recesses formed in one surface thereof in an array
Data Source
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AI summary
An object of the present invention is to provide a layered sheet and a method for molding a layered sheet molded product having excellent molding cycle time in which mold release can be performed without waiting for the molded product to be cooled to 60°C or lower and the subsequent molding cycle can be started. The object can be fulfilled by a layered sheet formed by layering a plurality of cloths comprised of thermoplastic resin strands and formed by layering a coating layer comprised of a thermoplastic resin onto at least one surface of the cloths, in which the thermoplastic resin is comprised of the same component as the strands and has a thickness of 0.02 mm or more and 1.0 mm or less, and a storage modulus of the coating layer at 150°C is 3.00 × 106 Pa or higher and 1.00 × 108 Pa or lower, and a method for producing a layered sheet molded product, the method including press-molding the layered sheet using a male-female mold press machine; subsequently mold-releasing a molded product obtained by the molding at a molded product temperature in a range of 70°C or more and 120°C or less; and subsequently lowering the molded product temperature to 60°C or lower.