Injection-Molded Translucent Component With Film Cut-Out Alignment
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Solution Overview
Problem
Existing methods for producing components with translucent plastic material fail to achieve precise and automated application of colored films on the rear side while ensuring the film is omitted from areas corresponding to front-side contours, leading to complex and imprecise results.
Innovation Solution
An injection molding method using a tool with a first part having negative structures for the front side and a second part with elevations and cut-outs for the rear side, allowing precise positioning of a colored film with pre-cut-outs, ensuring the film is applied only where needed, and using elevations to fix the film during molding.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If a colored film is applied to the rear side of a component by injection molding, then the color design is integrated into the component, but the film cannot be precisely omitted from areas corresponding to front-side contours
Solution Approach 1:
The patent applies preliminary action by pre-cutting the colored film with cut-outs corresponding to the front-side contours before injection molding. This allows the film to be precisely positioned and omitted from specific areas without requiring complex post-processing steps. The film is prepared in advance with the exact pattern needed, eliminating the need for laser cutting or other complex removal processes after molding.
Solution Approach 2:
The patent uses an intermediary approach by introducing a positioning system with corresponding positive structures on the injection molding tool that engage with the cut-outs in the film. This intermediary positioning mechanism ensures precise alignment of the pre-cut film with the mold cavity, allowing accurate omission of the film from areas corresponding to front-side contours while maintaining simple injection molding processes.
2Manufacturing precision
If laser cutting is used to remove the colored film from specific areas, then the film can be precisely removed, but the process becomes complex and difficult to automate
Solution Approach 1:
The patent eliminates the need for laser cutting by performing the removal action preliminarily - the film is pre-cut with cut-outs before injection molding. This transforms a complex post-processing removal operation into a simple preparatory step, enabling full automation of the manufacturing process without requiring automated laser cutting systems or manual intervention.
3Reliability
If the carrier layer of the colored film remains on the component, then the color layer is protected, but subsequent partial cutting-free becomes more difficult
Solution Approach 1:
The patent resolves this contradiction by performing the cutting action preliminarily - the film with carrier layer is pre-cut with cut-outs before injection molding. The carrier layer remains intact and provides protection during molding, while the pre-cut areas allow precise omission of the color layer where needed. This eliminates the need for subsequent cutting operations regardless of the carrier layer presence.
Solution Approach 2:
The positioning system with positive structures acts as an intermediary that engages with the pre-cut film, enabling precise positioning and omission of the film areas corresponding to front-side contours while the carrier layer remains in place to protect the color layer during the injection 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 simple, reliable, and automatable production of components with precise color design on the rear side, matching front-side contours, and achieving visually appealing illumination effects.
Implementation Method 1
the particular plastic material is liquefied and injected into a mold
Implementation Method 2
As a result of cooling and/or cross-linking, the plastic material returns to a solid state
Implementation Method 3
As a result of cooling and/or cross-linking, the plastic material returns to a solid state
Data Source
AI summary
In a method for producing a component (500) from a translucent plastic material (50), which comprises a front side having n contours (51), and in particular n raised contours, and a rear side covered with a colored film (40), initially an injection molding tool (100) is provided, which comprises a first tool part (10) and a second tool part (20), which together enclose a cavity (30) having the contours of the component (500) to be produced when the tool is closed. A surface of the first tool part (10) represents a negative of the front side of the component (500) and comprises n structures (11), in particular n indentations, corresponding to the n contours (51) of the component. A surface of the second tool part (20) represents a negative of the rear side of the component (500). The film (40) is positioned on the surface of the second tool part (20). The injection molding tool (100) is closed, and plasticized plastic material (50) is injected into the formed cavity (30). After the plasticized plastic material (50) has cured, the component (500) provided with the film (40) is demolded. In this method, the surface of the second tool part (20) is provided with n elevations (21), and the film (40) is provided with n cut-outs (43), prior to positioning, such that the n elevations (21) on the surface of the second tool part (20) engage in the n cut-outs (43) of the film during the positioning of the film (40).